Turbo issues

Wilddog4x4 · Mar 30, 2019

Ive been struggling for power and with huge amounts of black smoke under accelerations in my 300tdi defender and have narrowed it down to what i think is a dodgy turbo. Ive run it briefly with no air filter and checked the lift pump and the intercooler hoses and replaced one badly corroded injector (it idle’s much better now) I've also made sure the wastegate is functioning correctly, but have seen no differance in performance. So today I finally bought and plumbed in a boost gauge and it seems I'm only getting a maximum boost pressure of 6psi. Does this seem point to a broken turbo? The compressors vanes dont seem to be in too bad condition, but there is about 1.5 to 2mm of side to side movement in the turbo shaft. Id appreciate any insights into the problem before I shell out for a new turbo and it turns out it was just something simple. Ive also just had to replace the head gasket, I dont think its related though because It had the power issue before I did the head gasket.

Cheers
Aaron

Alfieslandy · Mar 30, 2019

Just thinking out loud here but have you checked the actuator is working properly? Maybe the wastegate is seized partially open? Try working the actuator rod to see if there is an issue.

Wilddog4x4 · Mar 30, 2019

Thanks for the reply. I've checked the actuator by running a airline to it and it seem to be functioning correctly.

Alfieslandy · Mar 30, 2019

Check intercooler and all pipework for leaks. Also the small bore pipe that runs from turbo to the back of injector pump. Does the impeller spin freely by hand? ( obviously only check this when engine is switched off for safety reasons )

Alfieslandy · Mar 30, 2019

Sorry just noticed you said you had checked ic hoses in your original post.

Wilddog4x4 · Mar 30, 2019

Ive plumbed the boost gauge into the wastegate actuators pipe so the intercooler should have no effects on the pressure im getting, also its a relitivley new full width alisport intercool so im really hoping its not leaking because it cost a fortune

. The impeller does spin freely, but I dont have a healthy turbo to compare it too so im not 100% sure what it should feel like. I haven’t checked the turbo to injector pump pipe, would that have a effect on the boost pressure im reading from the gauge?

Al2O3 · Mar 30, 2019

Wilddog4x4 said:
Ive been struggling for power and with huge amounts of black smoke under accelerations in my 300tdi defender and have narrowed it down to what i think is a dodgy turbo. Ive run it briefly with no air filter and checked the lift pump and the intercooler hoses and replaced one badly corroded injector (it idle’s much better now) I've also made sure the wastegate is functioning correctly, but have seen no differance in performance. So today I finally bought and plumbed in a boost gauge and it seems I'm only getting a maximum boost pressure of 6psi. Does this seem point to a broken turbo? The compressors vanes dont seem to be in too bad condition, but there is about 1.5 to 2mm of side to side movement in the turbo shaft. Id appreciate any insights into the problem before I shell out for a new turbo and it turns out it was just something simple. Ive also just had to replace the head gasket, I dont think its related though because It had the power issue before I did the head gasket.

Cheers
Aaron

With that amount of lateral movement it's carped.

Wilddog4x4 · Mar 30, 2019

Al2O3 said:
With that amount of lateral movement it's carped.

Thats what my initial thought was too. The only thing thats puzzling me is the fact that im not getting more boost pressure. I thought even with the lateral movement in the turbo shaft it should still spool up and although not at its most efficient it should give me more than 6psi boost?

Al2O3 · Mar 30, 2019

Wilddog4x4 said:
Thats what my initial thought was too. The only thing thats puzzling me is the fact that im not getting more boost pressure. I thought even with the lateral movement in the turbo shaft it should still spool up and although not at its most efficient it should give me more than 6psi boost?

Your turbo needs to spool up to 60, 70, 80K + rpm to reach max boost. Can't remember exactly, but it's scary fast. The bearings need to be in very good nick to allow that to happen.

Wilddog4x4 · Mar 30, 2019

Ok thanks that makes sense, I'll order a new turbo cartridge I might even treat myself to one of the nice billet hybrid ones. Hopefully that will sort the problem. Thank you to everybody for all your help.

nobber · Mar 30, 2019

Im pretty sure this turbo doesnt have bearings, it floats. Even brand new turbos have play, we have a brand new VW turbo on the workshop with a fair amount of play.
Black smoke would indicate over fueling, probably due to the turbo not spooling up, but a turbo not spooling up doesnt necessarily mean its broken.

nobber · Mar 30, 2019

Also, if it is goosed, get to the bottom of why its goosed before you fit a new one.

Wilddog4x4 · Mar 30, 2019

I think the next thing to do is take the turbo out and have a look at it. Is there anything in particular to look for?

nobber · Mar 30, 2019

Do you have a smoke pressure tester? My first port of call would be to hook it up to a pressure tester and check the induction system, then fuel system, that pipe from pump to turbo, check that too.

Wilddog4x4 · Mar 30, 2019

Ive driven it with the pipe from the back of the air box disconnected so I think that would bypass any blockage in the induction system. Im getting a lot of black smoke when I accelerate so I think im geting enough fuel, but im happy to be told I'm wrong. I'll check the turbo to injector pump pipe tomorrow thanks.

Al2O3 · Mar 30, 2019

nobber said:
Im pretty sure this turbo doesnt have bearings, it floats. Even brand new turbos have play, we have a brand new VW turbo on the workshop with a fair amount of play.
Black smoke would indicate over fueling, probably due to the turbo not spooling up, but a turbo not spooling up doesnt necessarily mean its broken.

Aye, my mistake. It'll be fine.

Britcyclerider · Mar 31, 2019

I've recently fitted a CHRA to mine (the cheapest refurb option) and there was only the tiniest bit of play in the bearings. Having said that, every 200 and 300 TDI engine I have looked at has a fair amount of play in the turbo and seems to run just fine!

Wilddog4x4 · Mar 31, 2019

Ok, I double checked the wastegate actuator this morning and even with 20psi the arm doesn't move. But the gate seems to be stuck in the closed position, so from what I understand I should still be getting more than 6psi of boost pressure when Im driving?

tottot · Mar 31, 2019

The standard pressure is 1 bar plus or minus .5. Yours is less than half that

neilly · Mar 31, 2019

tottot said:
The standard pressure is 1 bar plus or minus .5. Yours is less than half that

Cheers

Turbo issues

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