300 Tdi Rebuild

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Goc3k said:
Yep, once it thins - also possible it wont be as bad with the turbo under very little load



Basically a given nowadays there wont be what you need at halfords, does seem the prices are not quite as dreadful as they used to be mind - only had to give up a bit of liver last time i was in there rather than a whole kidney
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That air filter cost me £6.70 the same ones are £19.99 at Halfrauds.
I'm planning on taking it out on to the A road to Scotland and thrashing the feck oot of the 65bhp or whatever the non turbo'd engine might push out. ;)
 
Might be worth restricting the turbo outlet so that it can build some pressure as free flowing the turbo blades will not be loaded like in normal use.
 
Blackburn said:
Might be worth restricting the turbo outlet so that it can build some pressure as free flowing the turbo blades will not be loaded like in normal use.
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They should be more loaded because the energy absorbed by a turbo compressor is directly proportional to the mass of the gas which it is moving, so allowing it to flow like that lets it shift more air and loads it more.
That’s why the vacuum cleaner motor seems to speed up when you put your hand over the end of the pipe, you are taking much of the load off the motor (but robbing it of its cooling)
 
Blackburn said:
Does the density of the air at 1 bar pressure not increase hence the load on the turbine blades?
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That's correct pressure and temperature affect the air density and hence its mass, but the density at the impeller will be slightly less than ambient pressure, caused by drawing in the air through the filter, at the discharge point it will be higher. Its complex but most of the compression occurs in the volute (snail ) chamber where the velocity energy is converted to pressure.
On a multi stage turbo compressor the second stage will receive this compressed air usually about 1 bar G, and the mass is higher.


Sorry for the double post second one has a slight edit an my bloody phone managed to cock them up.
 
Bought another induction pipe (U bend) to set up the temporary filter. Was here when I got home from work so tried a new set up.
IMG_1718.JPG

It's taken in the dark with a torch for more light. You can just make out the blue filter down past the turbo.
The 90 degree elbo from the turbo is directed on to the inner wing.
IMG_1715.JPG

Tried to start her up but the battery was flat :mad: she's on charge and will try it again in a few hours. Was hoping to do a twenty mile test drive to get turbo hot to see if anything lands on the inner wing. Good job I'm patient o_O
 
Waited until 9pm and tried to start her. Fired straight up!:cool:
Took her for a spin to the next village and back. About an 8 mile circular route with a mix of flat, a short steep hill and about a 2 mile gradual uphill back to my village. Could hear the turbo whining like a stuck pig as I drove along.
Was planning two loops to give it a good test, but popped bonnet up after first loop.
oil from turbo on wing.JPG

Inner wing covered in oil :eek:
Decided that was enough proof so drove back home.
Turned the elbow pipe from the turbo outlet to have a look in.
oil in turbo exit pipe.JPG

More oil than used to turn up as @raywin's prediction.
Well I reckon that has blown James Martin's bad honing theory out of the water. And the idea that oil coming through the turbo would cool and pool in the intercooler. This oil was, more or less, passing straight through to be burned. Just leaving small amounts in the IC pipes which would trickle down and collect at jubilee pinch points. Looks like a brand new turbo is on the cards. Also looks like I might have built a half decent engine after all. :) Also! Having had two turbos off them that have been carp, the turbo reconditioning company I bought from are not good :( Caused me a lot of heartache and guilt :(:mad:
However, water still dripping from expansion bottle. :confused:
Water dripping from Expansion Tank.JPG

You can't tell from this picture but water is lying along the seem again.
Water on seem of expansion tank.JPG

Who cares? I think my engine is actually ok! :D
 
Al2O3 said:
Also looks like I might have built a half decent engine after all.
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Amen. I'm probably about as relieved as you - the attention to detail in your rebuild couldn't have gone wrong - it was confusing the **** out of me as to what was wrong with t'injun .... the turbo chucking that much oil out explains it - there is nothing wrong with t'injun....

All that work, and it's a bl@@dy ancillary! :mad: :rolleyes: I really do hope a new, proper turbo solves this...... :)
 
:)
Disco1BFG said:
Amen. I'm probably about as relieved as you - the attention to detail in your rebuild couldn't have gone wrong - it was confusing the **** out of me as to what was wrong with t'injun .... the turbo chucking that much oil out explains it - there is nothing wrong with t'injun....

All that work, and it's a bl@@dy ancillary! :mad: :rolleyes: I really do hope a new, proper turbo solves this...... :)
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Cheers mate. Really appreciate your interest and support throughout all of this. I suppose the adventure isn't over yet, but hopefully a new turbo puts an end to it. Can't wait to have an engine that's breathing properly :)
 
Al2O3 said:
:)
Cheers mate. Really appreciate your interest and support throughout all of this. I suppose the adventure isn't over yet, but hopefully a new turbo puts an end to it. Can't wait to have an engine that's breathing properly :)
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I think that many are looking forward to a happy conclusion to this story, you have put time, money, and effort in here it must be a relief to know what the problem was, and frustrating though it may be you know the problem was not one of your making.
 
raywin said:
I think that many are looking forward to a happy conclusion to this story, you have put time, money, and effort in here it must be a relief to know what the problem was, and frustrating though it may be you know the problem was not one of your making.
Click to expand...
Yeah, it's a big relief. To be fair though, it's been a great practical learning experience. Not to mention the amount of theoretical investigation into the function of the engine and ancillaries. It has been a pain putting the oil in all the time, plus the guilt of thinking you've cocked it up. So, to look on the bright side, if the engine had been fine from day one I wouldn't have learned so much and had all of this experience :rolleyes: :)
 
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