S40 V40: 2003 1.9d turbo failure -- Twice

[BazWithers]

Hello everyone, 1st post from myself. I need some help diagnosing a problem.

The Turbo has gone on my V40 1.9D. I figured it had just worn out. Started with a slight rattle, developed into a loud one and then the turbo started whistling. So I have changed the turbo for a used one, the spindle had no play and it seemed to be fine. Its lasted a week and now sounds just as bad as the original one, just hasn't started whistling yet.

car has done 159000 miles, I changed the oil and filter when I changed the turbo.

Any Ideas what could have made this happen? any help will be much appreciated.

[aldred309uk]

Maybe the oil line to the turbo is blocked?

[skyship007]

Originally Posted by BazWithers

Hello everyone, 1st post from myself. I need some help diagnosing a problem.

The Turbo has gone on my V40 1.9D. I figured it had just worn out. Started with a slight rattle, developed into a loud one and then the turbo started whistling. So I have changed the turbo for a used one, the spindle had no play and it seemed to be fine. Its lasted a week and now sounds just as bad as the original one, just hasn't started whistling yet.

car has done 159000 miles, I changed the oil and filter when I changed the turbo.

Any Ideas what could have made this happen? any help will be much appreciated.

If the turbo rotor was knocked out of balance prior to fitting it will take a week or so to chew out the bearings and fail. The main reason the rotor gets damaged by debris is the use of non OEM standard air filters or the failure of many grease monkeys to vacuum out the housing when changing the element, like wot it says in the Volvo software, but not the Haynes book of porkie pies that has the audacity to cover petrol jobs only.

If the previous abuser did not use a good major brand engine oil changed at a sensible interval, or the engine has a minor HG leak, then the oil feed line to the turbo can block up with varnish. The oil feed pipe is included in a good turbo fitting kit, although you can clean it out with acetone.

It takes quite a number of oil changes even with a high detergent oil to dissolve top end varnish deposits (Sludge in the sump is easy to shift with a few short oil & filter jobs), so if you think varnish or sludge might be an issue, try using a major brand oil flush additive designed for use at idle RPM just before changing the oil and filter (10 or 15 mins at idle). Avoid using any type of flush if you have oil leaks, as it can make them worse for a while due to the false oil seal effect.

[flyingtech55]

Originally Posted by aldred309uk

Maybe the oil line to the turbo is blocked?

It is generally a requirement to renew the turbo oil feed pipe and any associated filters when renewing a turbo. When a garage renew a turbo it either comes with a new pipe in the package or alternatively the supplier won't honour the guarantee on the unit unless proof of the fitting of a new oil feed pipe is provided.

HTH

TimR

[BazWithers]

Thanks for the reply guys, so possibly the oil pipe then, the used turbo already had the pipe on it.
I read another post in this forum re: egr valve needs cleaning and that it can be the cause of blown turbo, there was some oil In the pipe that goes to the inlet manifold and the manifold itself has a lot if soot and crud in it. Any thoughts?
Thanks again

[skyship007]

Originally Posted by BazWithers

Thanks for the reply guys, so possibly the oil pipe then, the used turbo already had the pipe on it.
I read another post in this forum re: egr valve needs cleaning and that it can be the cause of blown turbo, there was some oil In the pipe that goes to the inlet manifold and the manifold itself has a lot if soot and crud in it. Any thoughts?
Thanks again

The EGR function does not effect the turbo, BUT when you clean the EGR most sensible folks also clean the intake and that can result in lumps or Carbon going into the turbo when it's first run. Not an issue if you don't boot it as it starts, or vacuum out the intake after doing the cloth trick like wot is says in most good books on how to trash a diesel.

[aldred309uk]

Originally Posted by BazWithers

Thanks for the reply guys, so possibly the oil pipe then, the used turbo already had the pipe on it.
I read another post in this forum re: egr valve needs cleaning and that it can be the cause of blown turbo, there was some oil In the pipe that goes to the inlet manifold and the manifold itself has a lot if soot and crud in it. Any thoughts?
Thanks again

There's oil in the air manifold and intercooler from the pcv (positive crankcase ventilation) and oil is put into the air inlet system from that so it's nothing to worry about.

[BazWithers]

New turbo and oil pipe fitted, it was driving fine on the way home loads of boost. Was still making the noise so maybe it isn't coming from the turbo? Now the car has decided to boost only in the last 1500 of the the rev range.

[baldmosher]

If you get different behaviour with MAF unplugged then you may have found another issue.

[BazWithers]

Tried again today and it seems to have boost again, I tried first with the maf unplugged and then again with it plugged in and it didn't make a difference. I don't know if it made a difference but I had pushed the actuator arm in a few times to make sure it wasn't stuck open as a google search had come up with possible waste gate stuck open?
Any thoughts ?
I am going to post a video of the clicking/tapping noise seperatly in a minute