Ok, so on the way to the Autosport Show today chilling out. Gave it a little bit in 4th gear to ~4k rpm. Next thing there's a pop just like popping a boost hose off. Power is gone, and car appears sort of stuttery/misfiring (hard to explain, and the road was shaky to drive on). Checked my mirror, and as expected... LOTS of smoke. Typical signs of turbo failure basically :(

 

Due to the icy conditions I didn't want to pull over on the hard shoulder for safety reasons. So had to drive slowly a few miles until I reached the next junction. Oil temp was rising a bit due to burning oil (still not over 90 degrees C though). Pulled over and turned engine off. Checked oil level and still some oil showing on the stick. No warning light on dash either. Engine bay has LOTS of oil leaked out of somewhere all over it.

 

So... had to get recovered home. I popped home for a bit then straight down to my unit. Car pushed in and I stripped it down.

 

Upon removal, I noticed the following...

• Lots of oil in the TIP.
• Air filter looks like it's been sucked inwards slightly, as the shape is deformed a little from what it used to be. It is still fully intact however.
• Lots of oil in the boost pipework and inlet manifold.
• Turbo has NO play in the shaft side-to-side or in/out. Shaft has not snapped. Blades on both sides look in good condition.
• Oil feed pipe looks fine.
• Catch can and pipes look fine.
• EGR to inlet manifold gasket is perished. Which would account for me only making 2.3 bar recently.
• Lots of oil on the cam cover, inlet manifold exterior, on top of gearbox, on top of exhaust downpipe, some on ECU & bulkhead, and on the underside of the bonnet (see pic). However, absolutely NO visible oil on the exterior of the turbo or manifold.

 

Can anyone advise please? I want to get a turbo sorted asap, but I'm worried that I may potentially put one on and the engine is knackered. What I'm concerned about is why there's so much oil all over the place. I have had the standard turbo fail in the past and it left oil all around the brake fluid reservoir area, but not to the scale of this.

 

Pics...

 

 

 

 

 

 

Edited 16 January, 201610 yr by alex_e3

Please check the lines to and from your oil cooler as well as the cooler itself.

Could still be the turbo seal maybe, just because the bearings are ok doesn't mean its not pouring oil into the intake.

 

That doesn't account for all the oil in the engine bay though so there must be something else amiss, unless its come out between the hot and cold side of the turbo, any signs of oil there?

 

If you were boosting at the time that it went that's probably why it sprayed everywhere

Edited 16 January, 201610 yr by SuperbTWM

Cheers for the reply. One of my oil cooler hoses split at the wall a while ago, so it's been removed temporarily for a while now. Especially as it's cold anyway.

 

There's no oil present down the front or left of the block also.

Just spoke to Xman and he seems to think that oil seals in the turbo just going pop like that is unlikely :(

Just spoke to Xman and he seems to think that oil seals in the turbo just going pop like that is unlikely :(

 

 

Well there arn't many other ways that much oil can get into the intake unless the crank breather got blocked and it sucked a load in from the rocker cover breather, or maybe out of your catch can?

 

I used to run a catch can years ago and found in winter it used to fill up really quick due to moisture condensing inside it as it was at the front of the engine where cold air was coming straight at it.

How does the engine run?

Lumpy or as if it's missing?

I would advise you get a diesel compression tester and test each cylinder

I had very similar issue with my Polo GT turned out I put a hole in the piston and it blew all the oil out of the breather and oil filler cap due to crank case pressure, and all over the engine bay somehow

Edited 16 January, 201610 yr by silky16v

Oh no, don't say that! It's only just got put back on the road!

Maybe it's going to be those pushed injectors coming back to haunt people!

How does the engine run?

Lumpy or as if it's missing?

I would advise you get a diesel compression tester and test each cylinder

I had very similar issue with my Polo GT turned out I put a hole in the piston and it blew all the oil out of the breather and oil filler cap due to crank case pressure, and all over the engine bay somehow

 

 

To be honest I didn't run it for long after it went pop due to it consuming oil. Just had to get to a safe place first. When it did go pop though, I'll be honest I thought it felt like it was misfiring.

 

I was thinking compression test. I need to find someone who has one quickly! Failing that, pikey hook up the oil feed to the return pipe and see what it runs like with no turbo on briefly.

 

If it's gone then it may be time to start 16v conversion earlier than planned.

Edited 16 January, 201610 yr by alex_e3

Gotta be a boost pipe surely?

Gotta be a boost pipe surely?

Not with the amount of oil thats about, its something more serious

Dropped a valve maybe?

Gotta be a boost pipe surely?

 

Bloody hell, you don't know how much I wish it was that!!

 

 

Dropped a valve maybe?

 

I know it doesn't discount it completely, but I've literally just had the head rebuilt professionally with new seals etc...

 

 

 

I'll keep everyone updated with this. This happens the worst week possible - hardly any time to look at it this week. Plus away with work Thurs/Fri.

Bad times Alex :( , when my turbo failed Darkside recommended putting the oil feed into the where you fill the oil and plug the turbo oil return with something (I used a cork cut down) and run it with no manifolds.

Hopefully its nothing too serious.

I did the same as above when mine failed.

The oil return unscrews from the block with a multi spline so just put a nut and bolt in it to test it out.

Hope its nothing too serious and you get it fixed soon

Alex I'd also suggest wipping rocker cover off and make sure the injector followers are all still within spec, as if one if these is damaged u get a misfire, it's worth a look but I suspect something more serious tbh going from my past experience it's near exactly like my polo

Yep u will need a diesel compression checker not something u get down halfords I'm afraid

To push oil through the breather and catch tank u have to have massive crankcase pressure, this will explain why the tip is full and the boost hoses, why the air filter has sucked in I don't know is it upto the job or causing a restriction as the turbo comes on boost?

Hope u get resolved quickly if ya stuck for parts let me know have 2x ASZ motors in my lockup

Edited 17 January, 201610 yr by silky16v

Cheers for the support and replies guys.

 

It's one of those... if the engine is knackered then I can't complain too much - the damn thing was around twice the power of the standard one! I just would have preferred it has gone before I did all that work over the summer :(

 

 

 

Thanks Matt. Yeah to be honest mate I'm starting to think it's something serious. Especially the way it felt like it was missing. Air filter is the same one I've had on since before the 2260 went on and has been more than fine. I'm gonna see if I can get hold of a compression tester first. Then I guess I'll re-route the oil feed, sort the return, top up with oil and start.

To be honest, if it has gone, I'm not going to put a standard block back in...

 

2 litre 16v conversion will be started.

I already have a block here for a donor although I am planning on running a 2 litre 8v     Convert bottom end as my top end has had too much spent on it to change now.

I already have a block here for a donor although I am planning on running a 2 litre 8v     Convert bottom end as my top end has had too much spent on it to change now.

Will the gains be worth it?

As it's the 8v head that's the main restriction,as the 16v is a cross flow set up.

Will the gains be worth it?

As it's the 8v head that's the main restriction,as the 16v is a cross flow set up.

Not really but if I need a block anyway, just thought a rebore and two litre pistons may as well be done.