300 Tdi Rebuild

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Well, squirted water on and it got slightly worse for a second or two then stopped chirping. Brand new belt (Dayco) tensioner pulley pretty new (Britpart)
It's worse from cold, so I think I'll try again Saturday morning. Probably rules out the alternator bearing.
 
Al2O3 said:
Well, squirted water on and it got slightly worse for a second or two then stopped chirping. Brand new belt (Dayco) tensioner pulley pretty new (Britpart)
It's worse from cold, so I think I'll try again Saturday morning. Probably rules out the alternator bearing.
Click to expand...
Did you have a good look for the belt wandering on any of the pulleys and any of the ribs on the pulleys appearing to move?
 
Kwakerman said:
Did you have a good look for the belt wandering on any of the pulleys and any of the ribs on the pulleys appearing to move?
Click to expand...
Lots on tonight, so just quickly did the water thing. It was barely making much of a noise when I tried it, it tends to go off when it's warmed up.
 
Just had another look at the 'singing belt'. Started her up and it was quiet :mad: Revved it from the FIP and it started to chirp a bit. Squirted water on the V side of the belt and it stopped instantly. Took a video, but it didn't work, I mustn't have pressed the camera button hard enough :oops: The video would have shown the sound stopping and I then filmed each pulley wheel to look for movement, just as the guy does in the video @Kwakerman linked to above. Anyway, couldn't see any adverse pulley movement. Took the tensioner off. Looked fine, moves ok with a socket on it. Put a little oil in to the bearing (don't know if it has a dust shield in it) put it back on and chirping a bit again. I suppose next thing to try is a new belt. The fella in the video said Dayco belts were known for being noisy and he swaps his for a 'gator' backed one.

Exhaust sill smoking at start up and when revved hard. But, strangely, it hasn't used as much oil this week. Can't work that out.
This is the oil in the pipe going in to the inlet manifold today
IMG_6429.JPG

Mind you, that hasn't been cleaned out for two weeks..
 
Yes, I did. I remembered you mentioning it before so I specifically looked. Seemed fine to me. Seems tight there too, no movement.
At least it's ruled out the alternator! It's doing well that alternator. May well be the original, certainly been on for the 12 yrs I've had the Landy and it's done just over 100k in that time.
 
Al2O3 said:
Just had another look at the 'singing belt'. Started her up and it was quiet :mad: Revved it from the FIP and it started to chirp a bit. Squirted water on the V side of the belt and it stopped instantly. Took a video, but it didn't work, I mustn't have pressed the camera button hard enough :oops: The video would have shown the sound stopping and I then filmed each pulley wheel to look for movement, just as the guy does in the video @Kwakerman linked to above. Anyway, couldn't see any adverse pulley movement. Took the tensioner off. Looked fine, moves ok with a socket on it. Put a little oil in to the bearing (don't know if it has a dust shield in it) put it back on and chirping a bit again. I suppose next thing to try is a new belt. The fella in the video said Dayco belts were known for being noisy and he swaps his for a 'gator' backed one.

Exhaust sill smoking at start up and when revved hard. But, strangely, it hasn't used as much oil this week. Can't work that out.
This is the oil in the pipe going in to the inlet manifold todayView attachment 127484
Mind you, that hasn't been cleaned out for two weeks..
Click to expand...
Any update on the turbo after it went back for testing or is it all ok now?
 
Morning Kwakerman.
The turbo is still away as I took it off, left it on the doorstep, and went camping. Told them no hurry as I was away. However, they have emailed me to say they've stripped it down and can find no issues with it. They said the did see some minute metal particles but say these will be from the engine rebuild. I don't know if I should be concerned about that as I don't know if oil to turbo comes directly from tge filter? I changed the oil and filter after 250 miles.
 
Stripping down and not finding any issues is not the same as real-life testing a built up unit, you will also get build debris from pretty well any engine rebuild but I would expect the first oil/filter change to get rid of the bulk of that. Just have to keep fingers crossed and see what it is like when it is returned, if there was something not quite right with it the strip/rebuild may cure it.
 
Kwakerman said:
Stripping down and not finding any issues is not the same as real-life testing a built up unit, you will also get build debris from pretty well any engine rebuild but I would expect the first oil/filter change to get rid of the bulk of that. Just have to keep fingers crossed and see what it is like when it is returned, if there was something not quite right with it the strip/rebuild may cure it.
Click to expand...
The thought of it being better after a rebuild occurred to me too. We'll see.
I'd was topping the oil up every weekend. TBH the weekend I took the turbo off it took a lot less oil to top it up. Same weekly mileage. Still same level of smoking from the exhaust. It's a mystery to me, down to lack of experience and knowledge probably.
 
A quick update for anyone keeping an eye this. Got home from hols on Monday night. Phoned turbo recon company on Tuesday afternoon. They repeated their findings outlined in the post to Kwakerman above. I thanked them for checking it out and said box it up and tell me what the courier had cost. The guy said he was going to send me another one off the shelf. I said don't be daft, if it's checked out ok then just send it back. He insisted on sending another one and said it would be with me the following day. Sure enough it turned up today. Excellent service and attitude, I reckon. Very pleased with them.
I'm going to take the intercooler off again and flush it out, so that if any oil comes through with this turbo I'll know it's from the turbo and not been blown through from oil currently in the bottom of the intercooler body.
 
Well that's either very good service or the company are covering their tracks by sending a replacement. If the replacement stops the oil burning then its the latter, if it still burns then they are a good company but unfortunately you have issues elsewhere. Good luck and let us know how it goes.
 
Kwakerman said:
Well that's either very good service or the company are covering their tracks by sending a replacement. If the replacement stops the oil burning then its the latter, if it still burns then they are a good company but unfortunately you have issues elsewhere. Good luck and let us know how it goes.
Click to expand...
Hmmm........ that's what my Mrs said. 'There must have been something wrong with it, or they wouldn't send a different one'.
I'm not so sure. :(
It would be great if that's the source of the oil burning and exhaust smoke. The turbo was certainly passing a lot of oil. Thing is, I've no idea if it was within acceptable limits. I'll have a better idea soon enough though!
 
Well, got the replacement turbo fitted today. :)
Took the intercooler off and rinsed it through with petrol.
This is oil that must have been trickling down the bottom hose and gathering on the lip of the intercooler pipe.
IMG_6431.JPG

To be honest, there didn't seem to be much lying in the bottom of the intercooler.
This is the petrol that was used in the flush.
IMG_6433.JPG

That looks a bit worse than it actually was.
It's been glorious here today so perfect for drying out the intecooler up against a South facing wall.
Cleaned the IC pipes and inlet manifold with white spirit and then hot soapy water.
IMG_6434.JPG

Once everything was dry I put the new turbo in and fitted all the pipework back on. Filled the turbo bearing housing with oil, turned her over several times with the stop solenoid disconnected, then fired her up. Still smoked, but then if it's going to then that might take a while to clear out of the exhaust pipe. (fingers crossed)
Did the same run up the main road here as I'd done in previous tests so that it was a direct comparison.
She pulled and accelerated well. Still just getting up to about 0.8 bar, but this turbo is definitely more responsive as the boost needle responds more quickly. Had the Mrs in the car and she noticed this straight away.
Took the top IC pipe off and there was a lot less oil visible.
IMG_6438.JPG

Virtually non to be honest. Early days, but very pleased with the results so far. I'll have to see what a bit more driving brings.
I did notice that when you put your finger in and spun the blades this one spun far more freely. The previous one felt a bit tight when you tried to spin it and it only rotated about 1/4 of a turn and stopped suddenly when you spun it. This one spun with your finger far more easily and did about a full turn before slowly stopping.
As I say, early days, but seems to be a great improvement. :)
EDIT
Hmmm, the oil would have been burnt before it got to the exhaust. Ah, well. I'll see what happens.
 
Last edited:
Al2O3 said:
Well, got the replacement turbo fitted today. :)
Took the intercooler off and rinsed it through with petrol.
This is oil that must have been trickling down the bottom hose and gathering on the lip of the intercooler pipe.
View attachment 129643
To be honest, there didn't seem to be much lying in the bottom of the intercooler.
This is the petrol that was used in the flush.
View attachment 129644
That looks a bit worse than it actually was.
It's been glorious here today so perfect for drying out the intecooler up against a South facing wall.
Cleaned the IC pipes and inlet manifold with white spirit and then hot soapy water.
View attachment 129645
Once everything was dry I put the new turbo in and fitted all the pipework back on. Filled the turbo bearing housing with oil, turned her over several times with the stop solenoid disconnected, then fired her up. Still smoked, but then if it's going to then that might take a while to clear out of the exhaust pipe. (fingers crossed)
Did the same run up the main road here as I'd done in previous tests so that it was a direct comparison.
She pulled and accelerated well. Still just getting up to about 0.8 bar, but this turbo is definitely more responsive as the boost needle responds more quickly. Had the Mrs in the car and she noticed this straight away.
Took the top IC pipe off and there was a lot less oil visible.
View attachment 129646
Virtually non to be honest. Early days, but very pleased with the results so far. I'll have to see what a bit more driving brings.
I did notice that when you put your finger in and spun the blades this one spun far more freely. The previous one felt a bit tight when you tried to spin it and it only rotated about 1/4 of a turn and stopped suddenly when you spun it. This one spun with your finger far more easily and did about a full turn before slowly stopping.
As I say, early days, but seems to be a great improvement. :)
EDIT
Hmmm, the oil would have been burnt before it got to the exhaust. Ah, well. I'll see what happens.
Click to expand...
Well that certainly sounds like a good start..............now get out and drive the thing!:)
 
Kwakerman said:
Well that certainly sounds like a good start..............now get out and drive the thing!:)
Click to expand...
Certainly will. Have to fight the Mrs to use it! :)

neilly said:
Fingers crossed, all you have is clear roads in front and only smoky roads behind when you floor it going passed a load of bicyclists.

Cheers
Click to expand...
Hey, I was trotting up the road at 60mph! A few cars over took me, but I caught them up no bother. :) It doesn't smoke when I floor it though! When I rev it standing still on the drive it smokes. Although haven't tried that since I got back from the test drive and looked in the IC pipe when I got back. It must have been/possibly still is smoking as I'm going down the road, but it's not enough to see, presumably because of the air flow. Not from the wing mirror anyway.
 
Ok, at the risk of becoming irritating I thought I'd put another update on. :p
The Mrs drove the Landy to work for the first time today since the new turbo was fitted. She called me up at lunctime, "It's going like a rocket!" she said :D
It is anorl, tootling along at 60mph yesterday on the A1 I put my foot down to see what would happen. She flew up to nearly 80mph on the clock (That's about 73mph in reality cos my speedo is miles out) I eased straight off the pedal but she felt like she had a lot more. No boost pin or boost ring needed, she really is pulling hard and an absolute pleasure to drive. :D
 
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