Puma 2.4 Turbo Split in the Middle

[patclan]

Driving home last night going up a steep hill, I heard a bang and metal hitting the ground, then loss of power and the turbo was really loud.
Pulled over and got towed home, I had a look at it got today and I am kind of relieved it is not the internals.

At the same time it happened the battery light came on in the dash, I am not sure how it can be related unless something else is damaged, I am not sure what got hit by the metal on the way out.

Now to find a replacement without getting ripped off, and wondering if standard is fine or is there an upgrade.

Has anyone seen this before (see vid), and are there any special tools required to change it out?

Cheers Pat

https://youtu.be/WL2P2GPtF74

[Toxic_Avenger]

Ouch.
Looks like the hot side of the turbo has detached from the Center (CHRA)? Got any better pictures?
Some turbos have the intake and exhaust housings attached with a metal band clamp, some are bolted- not sure which the LR has... so that would be a possible failure point. But irrespective, youd have bent turbins shaft, munted compressor wheels etc.

Battery light was probably a consequence of whatever went FUBAR hitting the alternator harness which is directly in front of the bit that is now hangin in the breeze. Also check for damage there- melting of the loom, or mechanical damage- cut wires etc.

[big harold]

Demon Parts
GTB1749VK CCT Turbo Charger for Landrover Defender 2.2ltr LR042752 788479 × 1
They should do one for a 2.4

[patclan]

Ouch.
Looks like the hot side of the turbo has detached from the Center (CHRA)? Got any better pictures?
Some turbos have the intake and exhaust housings attached with a metal band clamp, some are bolted- not sure which the LR has... so that would be a possible failure point. But irrespective, youd have bent turbins shaft, munted compressor wheels etc.

Battery light was probably a consequence of whatever went FUBAR hitting the alternator harness which is directly in front of the bit that is now hangin in the breeze. Also check for damage there- melting of the loom, or mechanical damage- cut wires etc.

Thanks for that, I will have a good look tomorrow for more damage.
There does not seem to be a band clamp, and I have attached another photo and one of the replacement Turbo. It looks like the metal has sheered but it is hard to tell, I will have a better look tomorrow.

I have found a place on the Gold Coast Turbochargers Australia - Quality Aftermarket Garrett BorgWarner Turbos 24 month Warranty (https://www.turbochargersplus.com/) that has a non Garrett, probably chinese raplacement turbo for around $900, this seems to be half the price of a Garrett and I can pick it up tomorrow, 2 yr warranty so might be worth it, it is more the lead time that I am concerned about as I need the car for work. I am just hoping that they are legit.

179947179948
https://www.aulro.com/afvb/blob:chrome-untrusted://media-app/e4f78bf0-b278-4109-8c2f-899972c01b00

[Toxic_Avenger]

oh... that looks like the bracket that holds the actuator motor has sheared. Not as big of a problem if that's the case. The actuator alters the vane geometry of the turbine to change it's efficiency zones etc. Might have just rattled itself to death- in which case if you can get the thing disassembled, and get the parts somewhere to be welded together, or a new bracket plate cut, you'd probably have it sorted on the cheap.

[patclan]

I got the Turbo out, one of the studs was a real pain, the rest came out easy.
I think it is has seen better days :-)

I am hoping the missing bits fell to the ground, I found some small fragments of metal imbedded in the intercooler hose, not sure how I would clean the intercooler out without removing it, maybe stick the shop vac on the hose and see what it pulls out.

179963

[Toxic_Avenger]

Oof. Cold side impeller failure.
I'd be pulling the whole intake system out and flushing it good. If you can get a bore scope into the holes, you will have some extra piece of mind that the engine has ingested anything.
Inconel turbine blades VS a piston crown will always have the piston come out second best. And that would be an expensive repair.

[DazzaTD5]

Turbo failures are common on both the Defender 2.4 and 2.2 TDCi models as they are rubbish quality Garrett.
From memory about 2 years ago Garrett put in for chap. 11 bankruptcy, so the quality is not going to improve.
All the new Garrett are built in china, hence the failure rates.
I have fitted numerous turbos for 2.4 and 2.2, most are starting to show issues again after only a year or 2.
Caterpillar and Ford have had huge failure rates with Garrett.
You can buy online cheap **** "rebuilt" and "new" chinese ones for as low as $500, good luck with that.

I have since started to rebuild them using U.K manufactured cores, remanufactured turbo actuators and ceramic coated inlet / exhaust housings.

[patclan]

Turbo failures are common on both the Defender 2.4 and 2.2 TDCi models as they are rubbish quality Garrett.
From memory about 2 years ago Garrett put in for chap. 11 bankruptcy, so the quality is not going to improve.
All the new Garrett are built in china, hence the failure rates.
I have fitted numerous turbos for 2.4 and 2.2, most are starting to show issues again after only a year or 2.
Caterpillar and Ford have had huge failure rates with Garrett.
You can buy online cheap **** "rebuilt" and "new" chinese ones for as low as $500, good luck with that.

I have since started to rebuild them using U.K manufactured cores, remanufactured turbo actuators and ceramic coated inlet / exhaust housings.

I noticed when looking for a replacement the Garrett / Honeywell ones were made in China. I ended up ordering a Mellett, not sure if they are any good but from their site they're engineered and manufactured in the UK so here's hoping it lasts.

[DazzaTD5]

I noticed when looking for a replacement the Garrett / Honeywell ones were made in China. I ended up ordering a Mellett, not sure if they are any good but from their site they're engineered and manufactured in the UK so here's hoping it lasts.

The Mellett ones are good, I use the cores for my rebuilds.
I get some of my turbo parts from Turbo Rebuild limited New & Reconditioned Turbochargers & Turbo Parts (https://www.turborebuild.co.uk/)

[DazzaTD5]

I got the Turbo out, one of the studs was a real pain, the rest came out easy.
I think it is has seen better days :-)

I am hoping the missing bits fell to the ground, I found some small fragments of metal imbedded in the intercooler hose, not sure how I would clean the intercooler out without removing it, maybe stick the shop vac on the hose and see what it pulls out.

179963

Removing the intercooler is not hard, in fact it's easier than removing a turbo.

Place rags over the end of the arms of the wipers so when you lift bonnet up vertical you wont mark it.
Lift bonnet vertical and tie off with some soft rope cord etc etc (the door handles can be used to tie off)

Generally:
*you dont need to remove the bullbar.
*you dont need to remove the radiator.

Remove:
*top plastic fan cowling.
*front plastic apron.
*undo 3 bolts holding a/c condenser and jiggle a bit forward.
*undo 4 nuts holding slam panel and pry one end of the slam panel out (take care to not be too rough and damage stuff).
*dont loose the 4 spacers behind the slam panel (where the 4 studs are).
*unbolt the side plates that hold the intercooler in place (the bonnet stay is attached to one of them)
*remove side plates.
*undo turbo hoses.
*jiggle intercooler out carefully

*you could upgrade to an all alloy intercooler, its optional on a 2.4 as they dont often split the intercooler.
(the 2.2 it's a given the intercooler is going to split)

[patclan]

Removing the intercooler is not hard, in fact it's easier than removing a turbo.



Thanks mate!

I got the new turbo in, seems to work, going to do an oil change tomorrow. My big issue now is I think the turbo exploding has done something to the alternator, the battery led came on after the failure, but it got towed and never saw it again. New turbo and still have the battery light, ultraguage says 12v so nothing from the alternator. Have not found any broken cables so no idea. wishing I had bought a new alternator before fitting the turbo..