300 Tdi Rebuild

Right, I've looked at google images and my old strip down pictures. Looks like the long exhaust manifold pipe does go on the bulkhead side. I can't see how the mid section can move anyway. So, I'll have to try and mould the new pipe in to a shape that fits. @jamesmartin have you come across this problem before? I'm hung up on the fact that it seems to have occured since I rebuilt the engine.

Al2O3 said:

Do you not think the turbo is misaligned?

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Well, maybe - but I can't really see how, given the turbo is mounted to the central bit of the manifold, and that is mounted to the CH ..... hence my guess that the pipe fittings are misaligned - which I had on new genuine Hit@chi ( digger ) pipes early this year ...

Al2O3 said:

I'm off to google what the exhaust manifold set up should look like.

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I'll take some pics of mine tomorrow for comparison......

Disco1BFG said:

Well, maybe - but I can't really see how, given the turbo is mounted to the central bit of the manifold, and that is mounted to the CH ..... hence my guess that the pipe fittings are misaligned - which I had on new genuine Hit@chi ( digger ) pipes early this year ...



I'll take some pics of mine tomorrow for comparison......

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Pictures would be appreciated, thank you. Like you I've come to the conclusion the central flange of the exhaust manifold dictates the position, so I was clutching at straws there. I think the only thing I can do is try to remould the new pipe. I still can't understand how the old pipe, that worked and fitted before the engine rebuild, didn't work after the rebuild. And, the new pipe is the same

Al2O3 said:

Do you not think the turbo is misaligned?
The old pipe obviously fitted ok once before, but has ended up kinking when being fitted after the engine rebuild. It's as though it doesn't line up any more? You can't get a good view of that pipe from above and I've been focussed on a turbo fault or honing fault up to now, not a restriction in the outflow pipe. Now that I'm looking at the pipe it does seem misaligned. Don't know how though
I'm off to google what the exhaust manifold set up should look like.

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I would have thought the turbo position would be fixed by the manifold which is a substantial bit of iron.

raywin said:

I would have thought the turbo position would be fixed by the manifold which is a substantial bit of iron.

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It is, I was clutching at straws with being a desperate man

Al2O3 said:

Pictures would be appreciated, thank you.

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Here you go - excuse the oil leak - the PS reservoir pipe had let go - which is why I'm working on it anyway ...

That's nice and straight

Al2O3 said:

It is, I was clutching at straws with being a desperate man

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turbo cartridge can be rotated

I heated the new pipe in boiling water and shaped it in to a better fit.

So rather than straight it has a bend to take the apparent extra length out.
Fitted it and it still kinked.
Decided to chop a pipe up and make my own.
Cutting the braiding off was tricky. Went a bit too far here.

Cut all bar 8mm off the end and soldered some copper pipe on.

Cut some garden hose to length and heated in hot water to get it to push over the two ends.
Fitted without a kink.

I need a couple of jubilee clips on. And some sort of heat shield.

You're not really going to use garden hose surely? If it's just for a quick experiment, ok, but I'm pretty sure it isn't oil resistant and there's a fair potential for significant oil loss in short time if it lets go!

Britcyclerider said:

You're not really going to use garden hose surely? If it's just for a quick experiment, ok, but I'm pretty sure it isn't oil resistant and there's a fair potential for significant oil loss in short time if it lets go!

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I just need to order some silicone pipe off Amazon or eBay. It took a couple of goes to get the length of pipe right. It could still be about 5mm longer. I'm tempted to run it for a little while with the turbo outlet playing on to the wing again to see if it is still pushing out oil.

Ah, that makes sense! After following this excellent, but unfortunately long thread over the years, you really need some good luck with your Landy. May 2020 bring more enjoying and (a bit) less spannering!

Britcyclerider said:

Ah, that makes sense! After following this excellent, but unfortunately long thread over the years, you really need some good luck with your Landy. May 2020 bring more enjoying and (a bit) less spannering!

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Cheers, mate. I don't mind a bit of spannering, but looking forward to some more mundane stuff

Take care with the garden hose, the oil returning from the turbo is mad hot, the hose will go like plasticine when the engine heats up.

raywin said:

Take care with the garden hose, the oil returning from the turbo is mad hot, the hose will go like plasticine when the engine heats up.

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The silicone pipe is due to arrive on Friday so I'll just be patient and wait. I can't tell you how exciting the prospect of having a decent working turbo is! If it works I'm hoping that the seal rings will still be working on the turbo once the pressure is back to normal.

Al2O3 said:

The silicone pipe is due to arrive on Friday so I'll just be patient and wait. I can't tell you how exciting the prospect of having a decent working turbo is! If it works I'm hoping that the seal rings will still be working on the turbo once the pressure is back to normal.

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I'm sure lots of people who have followed this story will have their fingers crossed too, quite honestly the kinked hose seems to be a hot suspect in this story it would create a back pressure in the turbo and may force oil past the seals.
By restricting the flow it would also reduce the cooling effect of the oil on the turbo and thin the oil down.
Here's hoping.

raywin said:

I'm sure lots of people who have followed this story will have their fingers crossed too, quite honestly the kinked hose seems to be a hot suspect in this story it would create a back pressure in the turbo and may force oil past the seals.

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It is definitely something I will be checking as well, although I do not have the oil usage issue , it has highlighted the pipe kinking concern.

Cheers

raywin said:

I'm sure lots of people who have followed this story will have their fingers crossed too, quite honestly the kinked hose seems to be a hot suspect in this story it would create a back pressure in the turbo and may force oil past the seals.
By restricting the flow it would also reduce the cooling effect of the oil on the turbo and thin the oil down.
Here's hoping.

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I'm praying that kinked pipe is the culprit. I'm out of ideas after that

Silicone pipe arrived just after 3pm, so just enough light to cut to length and fit a bit of it.

Was looking forward to seeing oil gushing down through that pipe, so I got the Mrs to start it while I videod.


Interestingly:
1) it takes a few seconds to arrive after start up
2) it only trickles through!
Problem is that this pipe is usually covered in protective mesh, so not normally visible. Guessing people won't be able to tell me if the flow through that pipe is normal. My worry is that the kink in the pipe might not have been enough to hold that trickle back. Of course I don't know, the pipe might have been fairly well shut off.
I got the Mrs to put some revs on, but made no major difference. iPhone ran out of storage and so video stopped anyway, but wouldn't have shown much happening with a few revs on.
My new, expensive oil thermostat arrived today too. Not putting that in yet though, waiting to see what happens with just the new outflow pipe. Just doing one variable at a time
Now it's more time to wait to see what happens with the oil consumption

Apparently missed several pages when i first posted! A restriction has been found at last and only need a new turbo to eliminate everything else, haha. Fingers crossed you can close the thread at last now ey?