Injectors misbehaving but trying to understand the numbers

[darbuck]

Hi Lads, she's smoking heavily again, everything looks fine apart from timing angle she is -6 degrees retarded. This is obviously too much and would explain the white smoke. I know this can't be adjusted manually. I believe there is a TSB that when you change the fuel pressure regulator you have to change the fuel temperature sensor is this true? Is the signal from the fuel temperature sensor used to control timing? Can somebody with a known good rhr engine check the timing on lexia for me please or alternatively is there a guide value available?

[darbuck]

Just made a grim discovery that I think explains the smoke, oil coming from the turbo. I just booked in for NCT and had to cancel it again.

[MattBLancs]

Just made a grim discovery that I think explains the smoke, oil coming from the turbo. I just booked in for NCT and had to cancel it again.

Oh dear! Have you got at the turbo itself? Radial movement (side to side) generally ok (less than a millimeter say) but any perceivable axial movement (in/out) is bad news.

[darbuck]

Hi Matt, ran it tonight with engine flush and fresh 5w40 and filter it seems to have stopped leaking. I do however have increasing smoke as the engine warms. I pulled both of the intercooler hoses off but they are bone dry. I then ran it with the hoses off no smoke from the hoses but smoke from the exhaust. I done the stem seals when I redone the head she sounds really smooth. I am at a loss it's a bit weird.

[MattBLancs]

Very odd. Think it is possible to leak oil from turbo to exhaust side, but my understanding is that's rarer than to the compressor side. Would expect it to leak continuously though, not getting worse as warms up (I suppose oil thicker when cold. I suppose exhaust cooler so perhaps doesn't burn off at all untill a bit of exhaust heat has reached auto ignition temperature for the accumulated oil in the exhaust??)

Wait and see what others think, not much leaping to mind for me at present.

[darbuck]

Yeah it's a funny one, I do think it's oil pooling it's suggested to me to just drive it and see if it clears which I am a little bit reluctant to do because I could risk further damage but it could be what it needs. I did check for play in the turbo when I had the engine out because you can't check it on the car there's too much crap in the way. There was no play that I could detect in the shaft either.

[darbuck]

The valve stem seals were victor reinz incase anyone is wondering so not Chinese crap.given the history of the car I suppose it's possible it has the rarer version of exhaust seals I might try disconnecting the exhaust and scoping the pipework up to the rear of the turbo to see if there is oil passing into the exhaust if so it's a new turbo I suppose. It will probably be the weekend now. Finally got the new tyres for it though so a step closer.

[KennyW]

Worth getting your turbo checked over first and reconditioned. Rather than paying for new.

Kenny

[darbuck]

Hi Kenny , no I'm not buying one until I am certain. I can't scope it I forgot about the catalytic converter. I think I will remove the turbo and have a look at it. A bit of a pain but I need to know.

[darbuck]

Worth getting your turbo checked over first and reconditioned. Rather than paying for new.

Kenny
[/quote

Sorry Kenny I didn't read your post properly the other evening.I meant get it reconditioned rather than new.
I had put it all back together as I was convinced it was the fact the engine was leaning back from being on stands causing the oil to be sucked into the turbo. I can't scope it because I forgot about the pre-cat. I will remove on Monday and Tuesday hopefully with pictures to follow. Oil definitely dripping down onto the pre-cat has to be turbo failure. new head gasket and rocker gaskets I trust my work I have done several and know I was particular. There is no sign of leakage from them from what I could see with the scope. The only other thing with oil at the back i
Of the engine is the turbo and it's piping. I changed the PCV diaphragm because it felt very rigid, it didn't cure the problem though. I tried running her again after doing another oil change and left the oil at half full to rule out incorrect reading dipstick.
She is ok at cold idle but as she warms up or at high revs she starts to smoke and it just keeps getting worse at high RPMS until your surrounded by blue smoke which tells me it's turbo seals rather than dodgy new stem seals. She starts easily and there was no evidence of scoring on the cylinder walls when I had the engine apart so I don't believe it's the rings either and the engine is super smooth at idle.no knock or concerning tappet noises. I have ordered a smoke machine to help me diagnose further issues. The parts canon is put down at this stage.

[darbuck]

Ok so started removing turbo, you don't need to remove the subframe just the cross member and the rh drive shaft, engine mount and brackets. I think I will try and remove the turbo and pre-cat together and separate them off the ground. There doesn't seem to be much oil on the compressor side although there is a bit so I assume it's leaking on the exhaust side but I won't know until I remove it the rest of the way. There is a weird thing I discovered the inside of the oil return line is red and there doesn't seem to be much evidence of oil in it which is a bit concerning.

[darbuck]

Finally got it out it took most of the day but there's a bit of oil on the compressor side exhaust looks ok I think it's the seals gone on the shaft there is a bit of axial play and a tiny bit of back and forth but not huge there is a tiny bit of marking on the walls of the compressor side housing so it must be getting ready to let go. See pictures below. You can see on the pre-cat where it was running out of the compressor side at high rpm. The air feed pipe was allowing the oil past the o-rings as you can see as well. At least I'm certain now. A day to take it out god knows how long to reassemble. It needs a new turbo sourced one in Germany for €220 plus surcharge.

[darbuck]

New turbo arrived yesterday evening I'm now waiting on a new oil feed hose. Turbo came with new gasket kit. I'm going to put assembly lube into the top of the turbo and then turn her over with injectors disconnected to build oil pressure before I start her up to try and protect the turbo. There is a little filter in the lower bolt on the feed hose that disintegrated when I took it out is this necessary or can I get away without it. Is there any tsb on it?

[KennyW]

Well done Darren, I can't answer any of your questions about the turbo but I can give is lots of moral support. I can't think of anything else major which could cause problems as you have already done them.
This car should run for a long time as it's almost a 'new engine'.
Keep up the good work.

Kenny

[MattBLancs]

Filter in the oil feed? If it's like the 1.6 HDi DV6 advice is generally removed is best (said filter is prime candidate for blockage - starving the turbo if oil and giving that engine a reputation eating turbos)

The oil on the compressor housing isn't excessive in terms of what pictured - note also that is inlet - how much is on the other end of "the snail" ?

Also, how does the turbo shaft feel: wiggle test?