stumped with turbo diesel problem

[smiffy180]

Just had the turbo reconditioned due to oil starvation, a friend who is a mechanic has fit it all etc.

One of the seals on the injector isn't sealing properly so all are being replaced Tuesday when I can go and get one. This part is for information only incase it's relevant to the problem.

We've let it idle for about 10 minutes, run a diagnostic scanner and no codes found

Took the car for a 2 minute drive around our area, the car drives really smooth which is nice however there is no power? Or no power in comparison to before.

The car is a 2009 Fiat Bravo 2.0 diesel multijet running 213hp from a remap and dpf delete. It feels like it's running half that.

Prior to sending the turbo off whilst it was making horrible noises there was still boost there.

Any ideas?

[smiffy180]

Just taken it to the shop, the turbo seems to kick in about 2.5k revs instead of the 1.2-1.5k revs it was set up to when remapped.

Also my friend has been advised to check timing.

[Wild Child]

Boost leak maybe? The turbo does spin freely?

[smiffy180]

Wild Child said:

Boost leak maybe? The turbo does spin freely?

There's no noise to indicate this :/

As far as I'm aware it does

[Cemesis]

Actuator incorrectly adjusted? I'm guessing as its been a long time since I worked on turbo cars.

[smiffy180]

Cemesis said:

Actuator incorrectly adjusted? I'm guessing as its been a long time since I worked on turbo cars.

Erm I don't know, I'll mention it to him as he can't come back until tomorrow.

[Superhoop]

Check that the vacuum pipe from the variable boost control solenoid is connected to the actuator on the turbo. No control of blade angle = no boost at low engine speeds.

[smiffy180]

Will pass that on superhoop. Edit: he says he's checked them and the actuator was set at the place that reconditioned the turbo and should be correct?

just come back from shops and turbo was smoking, smelt a bit like burning. Is this just the paint/oil they've put on from refurb?

Edited by smiffy180 on Saturday 23 August 18:17

[Spangles]

According to Garrett, variable vane turbos can't be reconditioned, nobody else has the equipment to set them up. I've heard of more than one garage having to fit a brand new turbo after having the exact same problem.

[anonymous-user]

smiffy180 said:

Just had the turbo reconditioned due to oil starvation

Or, because the remap led to overspeed and bearing failure...............

[smiffy180]

Spangles said:

According to Garrett, variable vane turbos can't be reconditioned, nobody else has the equipment to set them up. I've heard of more than one garage having to fit a brand new turbo after having the exact same problem.

The company I used have garrett approved machines for this. 1 of 5 in the country apparently.

[smiffy180]

Max_Torque said:

Or, because the remap led to overspeed and bearing failure...............

Nope I mentioned this, when I explained it he thought it was due to this but the official engineers report was oil starvation

[MajorProblem]

Have you found the cause of the starvation? Blocked oil feed line / non return valve?

[sunbeam alpine]

Check the MAF. I spent ages buggering about with a turbo last year, only to find out it was the MAF, and the turbo was fine.

[smiffy180]

MajorProblem said:

Have you found the cause of the starvation? Blocked oil feed line / non return valve?

We did a oil flow test and it was fine?

Did wonder if it was due to last owner not allowing car to idle after a journey causing the starvation? This is just a guess.

I'm open to suggestions though

[smiffy180]

sunbeam alpine said:

Check the MAF. I spent ages buggering about with a turbo last year, only to find out it was the MAF, and the turbo was fine.

Would this show up on diagnostics?
Do you mean just replace it?
edit: just had a google. Recommended (on a vivaro van anyway) to disconnect the MAF and see if problems continue.

Edited by smiffy180 on Saturday 23 August 20:27

[sunbeam alpine]

smiffy180 said:

disconnect the MAF and see if problems continue.

This. Disconnect the MAF. If it runs better, replace the MAF.

[smiffy180]

sunbeam alpine said:

This. Disconnect the MAF. If it runs better, replace the MAF.

Cheers

[crossy67]

Superhoop said:

Check that the vacuum pipe from the variable boost control solenoid is connected to the actuator on the turbo. No control of blade angle = no boost at low engine speeds.

I'd go with that.

The MAF problem advice on Vivaros has not been correct on all the ones I have sorted. They run ste with or without the MAF connected, fit a new MAF and they still run crap until you reset the code in the ECU. Only weay to realy check them is to look at live data when the engine is running.

Regarding the injector seal. Not sure if the injector passes through the inside of the head but I'd assume it does. If there is any chance the leak from the injector has found it's way into the inside of the engine, ie the head then this could cause big problems. The blow by creates really sticky tar that hardens like cinder toffee. This can contaminate the inside of the engine and it's oil.

[anonymous-user]

smiffy180 said:

MajorProblem said:

Have you found the cause of the starvation? Blocked oil feed line / non return valve?

We did a oil flow test and it was fine?

Did wonder if it was due to last owner not allowing car to idle after a journey causing the starvation? This is just a guess.

I'm open to suggestions though

So, the turbo suffered "oil starvation" even though there was no apparent oil starvation?

(i'd bet the turbo oversped, and that lead to a dynamic loading the bearings couldn't deal with and hence they failed........)