ivancrx · Dec 11, 2016

1990 90 With Disco 200TDI fitted

I have been having a problem with oil being thrown all over the front of the engine and steering components. I have finally had chance to have a better look today and see what is happening.

Inlet manifold full of oil, pipe from intercooler to manifold full of oil.Intercooler has oil in it so does the pipe from the turbo to the intercooler.

Oil breather system all full of creamy mayo like oil and water.

New turbo fitted 18 months ago and only done 1500 miles.

What are peoples thoughts on this?

Cheers Ivan

Grem · Dec 11, 2016

What turbo was it? Genuine? cheap ebay replacement? second hand? reconditioned?

ivancrx · Dec 11, 2016

Grem said:
What turbo was it? Genuine? cheap ebay replacement? second hand? reconditioned?

It was a new set of internals (Cartridge), it was from a company in Liverpool IIRC genuine Melett replacement and not exactly cheap.

lynall · Dec 11, 2016

Mayo in oil wont be anything to do with the turbo failing as youve only done 1500 miles in 18mths its probably lack of use/cold running.
Again if the turbo has failed or is failing I dont see how it can spray oil all over the engine bay as the system is basically sealed from the turbo outlet to the exhaust pipe outlet.

ivancrx · Dec 11, 2016

lynall said:
Again if the turbo has failed or is failing I dont see how it can spray oil all over the engine bay as the system is basically sealed from the turbo outlet to the exhaust pipe outlet.

It looks like the oil has hit the fan and helped spray it about a bit.

Kwakerman · Dec 11, 2016

You need to be very wary if you have a lot of oil in the inlet system as that is a prime recipe for a runaway engine. I would be tempted to pull the intercooler / pipes / inlet manifold and give it a good clean out and go for a gentle run and have another look. If the oil is back sounds like a duff turbo. Worth preparing for the worst and rehearse what you would do if you do have a runaway (carry and have to hand) the options to try and stop it are
Stall it (if you are quick).
Block the air intake (thin sheet of flexible rubber perhaps but you also need a well sealed air box etc).
CO2 fire extinguisher down the air intake (don't try dry powder).

Next door has his transit run away on the M3 a couple of weeks ago, didn't know what to do and ended up walking away until it died, now looking at scrapping the vehicle due to replacement engine costs!

lynall · Dec 11, 2016

ivancrx said:
It looks like the oil has hit the fan and helped spray it about a bit.

Ivan I think you have missed the point, if the turbo seals are leaking all the oil/smoke will only come out of one place the tail pipe, unless you have a split hose it simply cant get out inside the engine bay.

flat · Dec 11, 2016

if the fan has sprayed it around a bit could an oil cooler pipe be leaking, or leaking at the rad/oil cooler area?
Oil in the inlet pipes maybe a red herring, my thinking being that the only oily bits near the fan, that would be able to be flicked around, would be either oil cooler pipes or PAS pipes. If it was something leaking from the block into the timing chest etc that wouldnt get flicked around by the fan. If it was the rocker leaking enough to spray onto the fan then i think you would notice it from there.

some one correct me if i am wrong, just thinking out loud.

lynall · Dec 12, 2016

Good point ref the cooler hoses.
Maybe a good clean up and run it at idle to see wheres its leaking?
Brake cleaner is real good at cleaning up oil, dont smoke as its flamable and if inhaled through a cigarette you wont have to worry about oil leaks ever again!

ivancrx · Dec 12, 2016

flat said:
if the fan has sprayed it around a bit could an oil cooler pipe be leaking, or leaking at the rad/oil cooler area?
Oil in the inlet pipes maybe a red herring, my thinking being that the only oily bits near the fan, that would be able to be flicked around, would be either oil cooler pipes or PAS pipes. If it was something leaking from the block into the timing chest etc that wouldnt get flicked around by the fan. If it was the rocker leaking enough to spray onto the fan then i think you would notice it from there.

some one correct me if i am wrong, just thinking out loud.

ivancrx · Dec 12, 2016

Many thanks for the help

The radiator/oil cooler is new so wouldn't suspect this to be the problem. The PAS fluid is red in colour and it is definitely emulsified oil that is over everything.

There was definitely a lot of oil from the intercooler pipes which made me think Turbo, I know it is a sealed system so to speak but I could pour the oil out of the top hose from the inlet to the intercooler.

Marmaduke · Dec 12, 2016

Take the breather pipe or the air intake pipe and disconnect and remove the turbo / intercooler pipes and run the engine after you've cleaned any oil from the turbo blades. Hopefully that will show if the turbo is leaking or if it's excessive crankcase pressure

lynall · Dec 12, 2016

Simple test of crankcase pressure is with engine hot and running at idle loosen the oil filler cap if it rattles around all is good, if it blows off its fooked!

ivancrx · Dec 12, 2016

lynall said:
Simple test of crankcase pressure is with engine hot and running at idle loosen the oil filler cap if it rattles around all is good, if it blows off its fooked!

Its fooked then, It is blowing like an old soho lady. I am assuming bore wear?

Will I also be looking at a new / replacement Turbo?

ivancrx · Dec 12, 2016

I have attached a couple of photos from when I stripped it down a few months ago when I had to replace the head gasket (Twice).

Marmaduke · Dec 12, 2016

I can't really tell by looking at your pictures, the honing marks should be visible and uniform all around the piston bores.

ivancrx · Dec 12, 2016

Marmaduke said:
honing marks should be visible and uniform all around the piston bores.

Er what honing marks lol.

There wasn't a great deal left of them, but never had any problems like this until I did the head gasket.

Marmaduke · Dec 12, 2016

That's probably because the pressure was escaping through the gasket not past the rings...

ivancrx · Dec 12, 2016

Marmaduke said:
That's probably because the pressure was escaping through the gasket not past the rings...

Very good point, oh well, its had a top end rebuild so why not a bottom end rebuild as well, give me something to do over Christmas I suppose.

Do you think the turbo will have escaped?

Marmaduke · Dec 12, 2016

I hope so for your sake, you're going to have fun cleaning all the oil out of your rad/oil cooler. I've got a set of machine mart honing stones, timing locking set and a piston ring compressor if you want to borrow owt.
Sounds like you've got more time off over Christmas than me

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