Catastrophic Engine/turbo failure

**Niles** · Thursday 12th January 2012, 23:09

OK, sadly, here I go. had a 19T compressor housing and the compressor wheel (brand new). Took the 16T off. Put the 19T compressor and the wheel on (used a good 16T centre core and exhaust housing).
Built the turbo up very carefully, everything worked as it should. Bolted on. Took it down the road. Very strange noise from the turbo. Tippy toe'd my car back to the workshop. Took the intake pipe off and the compressor wheel was easy to spin with 1 finger. No problem. Checked everything. No problems.
Took the car back out. Drove up to the A2. Drove down it. Squeezed the accelerator. Strange noise still there....hmmmmmmm 'what the hell is that?' (other than absolutely NO boost). Drove on BANG!!! TONS AND TONS of smoke from the car. Pulled off the A2 1 mile later and went back to the workshop. The tailgate and rear screen were COVERED in oil.

Pulled the turbo off.

Exhaust turbine??!! Missing??!! GONE!!!!!

Turbo centre shaft snapped. Had a look at the turbo and the compressor wheel had locked up on the 'alleged' 19T housing. Turbo had locked up under positive Pressure.

Removed the downpipe and out rolled the exhaust wheel.
Pipe was dripping with oil. Engine lost appx 3 litres of oil (exited the oil system via the turbo straight into the inlet system).
Exhaust tip was dripping oil.
Threw the turbo across the workshop and put a good (known working order turbo back on.
Now.......still S#it loads of smoke (white/grey) and a tap tap tap.

Suspected......Head gasket failure, and....bent rod. And, entire intake system needs totally cleaning of oil (and theres LOADS of it), exhaust and downpipe needs de'oiling. Spark plugs are covered. Lambda sensor very oily.

WARNING!!!!!>>>>> DO NOT BUT A 19T turbo from Kinugawa turbo on ebay.
Had the compressor checked and the housing wasn't machined to accept the wheel. (shed load of score marks on the wheel and housing). (destroyed the wheel too).

Seller states theres nothing wrong and swears the housing was machined. Score marks are evidence thats rubbish.

To say I'm angry with.........
Kinugawa Turbo (ebay) (Japanese turbo people) is a major understatement. Car will now be off road until further notice.

To busy with work to pay major attention to my poorly baby.
Late Monday will see the exhaust/intake strip/clean and a further diagnosis.
Compression test sometime tomorrow to see if its a bent rod or a tappet just starved of oil and hopefully its a tappet so a good flush and fresh oil will shut that up.

All I want to say is....durygbveiugv jkfh kuefh bhfsei nadj alfjvncm.

(That's Martian for a lot of swear words).

FFS!!!!!!!

**The Flying Moose** · Thursday 12th January 2012, 23:14

Very sorry to hear about your incident, hopefully worst case is as you say... tappet or lifter.

**dalhousie2008** · Thursday 12th January 2012, 23:20

Glad you put that post on niles, was ordering one of those, very sorry to hear the news buddy. Have you got a spare engine if rods are gone?

**M-R-P** · Thursday 12th January 2012, 23:22

Wow, thats pretty nasty luck. Hope the damage is minimal.

**Robs-P2-v70t5** · Thursday 12th January 2012, 23:23

one like this ? http://www.ebay.co.uk/itm/2906517726...84.m1423.l2649

if so that will be coming out of my watch list!

you must be really gutted and i understand fully why your livid. hope the rebuild goes well for you without to much internal damage, fingers crossed for ya that its just a tappet.

**tattoo101** · Thursday 12th January 2012, 23:26

sorry to here that buddy. can you not claim anything from the ebay turbo dudes?
hope you can get back on the road soon

**Niles** · Thursday 12th January 2012, 23:34

Originally Posted by dalhousie2008

Glad you put that post on niles, was ordering one of those, very sorry to hear the news buddy. Have you got a spare engine if rods are gone?

no spare good engine. BUT...... just rang a mate. hes got spare rods and tappets/lifters. If it is that he's coming over mid week and both of us cracking on on it can take its head off, sump off, switch the rod and gasket same day. I know my stem seals a very tired so bonus, they'll get done too.

**Kingsford G** · Thursday 12th January 2012, 23:36

Sorry to hear that mate.I hope it is a tappet and the compression is good.

**Niles** · Thursday 12th January 2012, 23:36

Originally Posted by tattoo101

sorry to here that buddy. can you not claim anything from the ebay turbo dudes?
hope you can get back on the road soon

they said they will only refund the money if I send it back and they see its never been used/fitted!!!!!! How the f can you tell its not a proper job unless its fitted???!!!
The turbo when it was built up was spinning freely. Only under positive pressure it would lock up. (hence the funny whine noise).

**JUDGENINJA** · Thursday 12th January 2012, 23:37

Hopefully if it is just the exhaust housing that has disintergrated then the inlet side of things may be OK. I'm hoping any water cooling that has just mixed with the oil on the sump side of things.. quick change of the oil make fix this..

**Niles** · Thursday 12th January 2012, 23:37

Originally Posted by robs-p2-v70t5

one like this ? http://www.ebay.co.uk/itm/2906517726...84.m1423.l2649

if so that will be coming out of my watch list!

You must be really gutted and i understand fully why your livid. Hope the rebuild goes well for you without to much internal damage, fingers crossed for ya that its just a tappet.

yes. Thats it

**daza-b** · Thursday 12th January 2012, 23:37

if you need any help with anything let me know bud...im guessing your miles away from me??

**mitchyboy01** · Friday 13th January 2012, 00:00

Not good mate, not a good day for volvos in our neck of the woods. I know you will have it sorted in no time though. Good luck.

**t5_monkey** · Friday 13th January 2012, 00:09

Damn sorry to hear that dude.

Ebay... tuning... always made me a little nervous.

**siamblue** · Friday 13th January 2012, 01:04

Sorry to hear that Niles, did you not get the turbo balanced before you fitted it all back together? these things spin at ridicouless rpm's. also you would've needed a 19t map as well.

Gary.

**Wobbly Dave** · Friday 13th January 2012, 01:20

Sorry to hear of your woes. It is never nice when things go badly wrong with tuning/ mods. Been there too many times.

I hope everythiing is sorted soon.

**glock19** · Friday 13th January 2012, 01:20

Nils, gutted for me mate

I just made an enquiry for the 19T wheel, housing and the works last night albeit from a different supplier (Jap too) so this'll be a caution for me too. You did not however, mention if you machined your CHRA to accept the bigger compressor wheel. No doubt there is not rotation play, was there any lateral movement ? The lateral movement will shift the wheel towards the compressor housing under load and jam up the compressor wheel.

Your 16T has a straight flange or an angled one ? I think both of these CHRA are slightly different (do correct me) and the parts might be sent wrongly. The wrong parts could give the above lateral movement

**I want a T5** · Friday 13th January 2012, 04:24

Thats a real bummer dude........tell me about it tomorow morning!

**wegal** · Friday 13th January 2012, 10:17

Damn mate that sucks big time. Like everyone else I hope that the damage is minimal.

Im not all that clued up but I dont understand how it can bend a rod with a jammed up turbo, always thought bent rods came from over boost. Can the turbo bits get inside the engine block ?

Scary thought that one is :-(

Hope you get it sorted quickly and cheaply.

**mitchyboy01** · Friday 13th January 2012, 10:28

Originally Posted by siamblue

Sorry to hear that Niles, did you not get the turbo balanced before you fitted it all back together? these things spin at ridicouless rpm's. also you would've needed a 19t map as well.

Gary.

Yes I thought they had to be balanced as they have such small tolerences? Maybe if it wasn't balanced properly this could lead to failure?

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