Thread: cracked turbo manifold

Originally Posted by fraser130

I'm pretty sure the turbo is cooled and lubricated by oil, it should hav a small metal braided hose go in the top, and a larger pipe come out the bottom to let the oil drain back into the sump.
I hope you didn't run it with no oil pipes connected!

Fraser

nope there fine and we checked that it was getting oil to

Sorry only just seen this thread.

The noise is most likely a leaking manifold gasket.

I assume you have fitted a new exhaust manifold and turbine housing (the pics are poor quality, but it looks like the turbine housing was cracked, not sure what else was cracked.

If I had seen this thread earlier, I could have given you a used turbine housing (but turbo has worn bearing).

What makes you think the waste gate is not set up correctly? What part is it that is not correct - length of linkage?, boost pressure hose to actuator?, high boost pressure?, low boost pressure? - you need to give more info if you want help!

Originally Posted by Bush65

Sorry only just seen this thread.

The noise is most likely a leaking manifold gasket.

I assume you have fitted a new exhaust manifold and turbine housing (the pics are poor quality, but it looks like the turbine housing was cracked, not sure what else was cracked.

If I had seen this thread earlier, I could have given you a used turbine housing (but turbo has worn bearing).

What makes you think the waste gate is not set up correctly? What part is it that is not correct - length of linkage?, boost pressure hose to actuator?, high boost pressure?, low boost pressure? - you need to give more info if you want help!

yea i fitted a new gasket, the reason i think it is that the wastegate is not set up properly is because when we went to join the arm it didnt line up so we had to lengthen the linkage i think im going to get a boost guage and have a look at it

Originally Posted by disco_mitch

yea i fitted a new gasket...

So I take it that the new gasket fixed the noise!

Originally Posted by disco_mitch

... when we went to join the arm it didnt line up so we had to lengthen the linkage ...

Whooah.

You need to put it back how it was.

You have to pull the rod against the spring inside the boost actuator to get it to connect to the lever on the wastegate.

The spring force is needed to hold the gate closed against the exhaust pressure and the boost pressure supplied to the actuator.

Edit: Stock boost pressure should be approx 14-15 psi for a 300Tdi. By shortening the rod (increase spring pre-load) you can safely increase boost pressure to about 18 psi for improved performance (particularly with an adjusted fuel injection pump).

Originally Posted by disco_mitch

just doing it now and it lloks like there is oil going through the cooler hose and is leaking big time what does this mean

When the turbo wears, it is common for oil to leak into the compressor and find it's way into the intercooler. The oil generally accumulates inside the intercooler and performance suffers.

The other way (besides worn turbo) for oil to get there, is from the engine breather. The breather hose is connected to the hose between the air cleaner and the compressor.

Excess oil from the breather is an indication of possible worn piston rings.

Originally Posted by Bush65

So I take it that the new gasket fixed the noise!

Whooah.

You need to put it back how it was.

You have to pull the rod against the spring inside the boost actuator to get it to connect to the lever on the wastegate.

The spring force is needed to hold the gate closed against the exhaust pressure and the boost pressure supplied to the actuator.

Edit: Stock boost pressure should be approx 14-15 psi for a 300Tdi. By shortening the rod (increase spring pre-load) you can safely increase boost pressure to about 18 psi for improved performance (particularly with an adjusted fuel injection pump).

ah this all makes sense now i didnt even realise there was a spring loaded part ill get a boost guage this week ad fix it all up

is 15psi right that sounds like to much i thought it was supposed to be 8 although i could be wrong

Originally Posted by disco_mitch

is 15psi right that sounds like to much i thought it was supposed to be 8 although i could be wrong

15 psi boost pressure is stock setting for a 300Tdi. The stock boost pressure for a 200Tdi is less (12 psi from memory but I stand to be corrected).

You shouldn't have any problems if boost pressure is increased to 18 psi.