Zonker's Callaway Turbo Rebuild Story

The Zonker has always been referred to as the 16v Callaway Turbo GTI Syncro. The turbo is one of the two reasons that makes the car so unique. And let me tell you how unique.

After getting the Zonker home and taking it out on its maiden drive. It was not performing, as it should have. After some testing we found that the boost from the turbo was at 2 lbs. Not what we wanted to see so off comes the turbo, down pipe (See related story Zonker's Down Pipe Story) etc. You would think a Garret turbo with the part # 107100-0 and serial #  YJ-L 0103 would be a call to the turbo shop to get a rebuild. HA! Now I know what one of a kind means. After that failed searching the web talking to anyone who would listen, calling every company that had turbo in their name.

Finally I found Jeff at Turbo Auto in Tennessee. After receiving the turbo Jeff found that it was made for Callaway. By who? Well working backwards Garret, Roto-Master, Rajay.  It turns out that it is a Rajay Compact, used in formula racing. Jeff completed the rebuilt and in testing what did he find? The waste gate is setup for 25-30 lbs. of boost (this is what most of the 2 liter formula cars ran in 1988 25-35 lbs.). Now the big question is has the turbo ever worked? Callaway's 2-stage turbo system only claims 10-15 lbs. The Zonker's Garret, Roto-Master waste gate part # 300118-05 serial # VJ-L0103 is setup for 25-30 lbs.??

With Jeff's help we re-calibrated the waste gate to 15lbs of boost.

Below are photos of Jeff's work, if you need turbo work give him a call 615.383.6242 or visit his web site www.turboauto.biz