Topic: turbo transplant (Read 1456 times)

mjohnson · « **on:** January 04, 2009, 01:17:22 PM »

well after a few days of troubleshootin g (with the help of c3cars and mostly nate) and months of procastination I finally got around to fixing the problem of smoke on the decel. I first tried rebuilding the K03s, mainly for the experience, but that didn't fix the problem. Following Nate's lead I checked the case vent which was good. That led me back to a bad turbo. As much as I wanted to go bt I saved the cash and found a brand new K04 of fleebay for 400 bones. Guess you could say that was my christmas present to myself since I bought it on christmas, haha. After clearing the garage of the jeep project I commenced to swapping the turbo yesterday around noon. Total time was about 6hrs including 2 meals and a trip to the store. I'm impressed, considering last time it took me a couple days I think (putting it back in sucks monkey balls unless you have a game plan like I did this time).

Well, being as words mean nothing here...below is the approximate 4hrs of actual work in less than 2 minutes

http://www.youtube.com/v/fZwmtssr-Ok&hl=en&fs=1

Giggidy · « **Reply #1 on:** January 04, 2009, 02:24:32 PM »

very nice

how does it run??

mjohnson · « **Reply #2 on:** January 04, 2009, 03:24:33 PM »

Everything works gr...fine!?!

The smoke is gone

but it just doesn't seem to have the pull that the K03s had.

The K03 would peak at around 21psi and run at about 17, but the K04 (besides the very first hit of the throttle where it peaked at about 24psi) peaks at about 10 or 11 and runs at 7. I have a feeling adjusting the wastegate will help but first I'll go through everything again making sure there are no leaks fluid/vac and then I'll be heading up to APR to have them update my chip for my new setup as well as some other stuff.

DutchVDub · « **Reply #3 on:** January 04, 2009, 03:54:22 PM »

The K04 will probably have a bit of lag compared to the KO3, but its still a far better turbo. Nice work.

101stvet · « **Reply #4 on:** January 04, 2009, 05:27:05 PM »

well played with the vid

oliver · « **Reply #5 on:** January 04, 2009, 07:33:24 PM »

So you upgraded from a ko3s to a ko4_01 right?. Bolts up into the stock manifold unlike the audi TT ko4.

mjohnson · « **Reply #6 on:** January 04, 2009, 08:09:50 PM »

Quote from: oliver on January 04, 2009, 07:33:24 PM

So you upgraded from a ko3s to a ko4_01 right?. Bolts up into the stock manifold unlike the audi TT ko4.

Yep. Super easy.

Quote from: Giggidy on January 04, 2009, 02:24:32 PM

very nice how does it run??

Well um, something gave out tonight.

I took it out this morning for a nice 45 min or so drive. Driving it like normal with the occasional hit of the gas. Everything seemed fine. No smoke, just nothing higher than 7psi.

I took off from the pad on to the main street and gave it a health dose of throttle. This time it hit 20 or so psi I'm guessing, I wasn't really watching because I didn't expect it to jump; but then there was a sound followed by engine cutting out with loss of easy brakes...exact same symptoms as if you were to pull the hose of the break booster, no biggie. Well, the hose was still connected, but I disconnected it just to make sure, and it died. After reconnecting it I started the car up again and it had a bad idle for a bit with some white/blue smoke and then it cleared up and idle fine again. I give it a shot to finish my short trip, everything is fine..for a while. I tell my buddy to look back to see if there is any smoke, "nothing". No sooner did he say that and turn around that all of a sudden this white/blue smoke started pouring out. BAD. Like when james bond hits the smoke screen button on the aston. Like, I couldn't see the headlights of the guy behind me. I pull off the road, let the smoke clear and headed back home. I had other things to take care of but later on when I looked under the car there were no leaks.

I'm going to check the compression again tomorrow and also see if I can't do a leak down test as well. Any other ideas?

SwiftMKIII · « **Reply #7 on:** January 04, 2009, 08:33:10 PM »

No FI experience, but sounds like what I hear of turbo seals going. That would really suck being a new turbo, but maybe warranty?

scurvy_bandit · « **Reply #8 on:** January 05, 2009, 07:51:43 AM »

Damn dude... that is some shitty luck man. I would be hitting them fools up for a warranty

Jesus · « **Reply #9 on:** January 05, 2009, 09:34:03 AM »

Sounds like a bad turbo

mjohnson · « **Reply #10 on:** January 05, 2009, 09:50:00 AM »

Oh yeah, it smokes a healthy bluish/white cloud all the time now, no matter if it's idling, accel, or decel.

LOS · « **Reply #11 on:** January 05, 2009, 09:50:55 AM »

echo.... youre new turbo is shot man

scurvy_bandit · « **Reply #12 on:** January 05, 2009, 10:01:06 AM »

Man... it def sounds like bad seals. If its blue and white it could be a head gasket? Have you looked at your oil or coolant yet? If its mixing some that could be the issue. I hope for you that isnt the case, but if it is just time to get a nice multi layer gasket! NGP?

mjohnson · « **Reply #13 on:** January 05, 2009, 10:01:22 AM »

ok, well luckily I went with my gut instinct which said "if you're going to get a turbo off ebay, make sure it's brand new and they offer warranty". I guess I'll start on the claim. while I'm waiting on that I think I'm still going to do a compression test.

here is a quote from a dude on c3cars about the issue...

"Check your oil and a compression test like you said. If its low (compression) a splash of oil in that cylinder then check it again. If it goes back up its your piston rings. But that amount of smoke almost sounds like leaky valve seals."

mjohnson · « **Reply #14 on:** January 05, 2009, 10:05:42 AM »

Quote from: scurvy_bandit on January 05, 2009, 10:01:06 AM

Man... it def sounds like bad seals. If its blue and white it could be a head gasket? Have you looked at your oil or coolant yet? If its mixing some that could be the issue. I hope for you that isnt the case, but if it is just time to get a nice multi layer gasket! NGP?

I've still got a head gasket waiting for this one to blow, haha. Oil and coolant aren't mixing, when I say bluish I mean just a slight tinge, but it's most definitely burning oil, I can taste it, haha.

I don't think that's the issue however.

oliver · « **Reply #15 on:** January 05, 2009, 10:29:28 AM »

Here's my old ko4 back in 2004 which gave up on second creek raceway. Got 6k miles on it when it blew, white smoke, loss of compression, rings were shot too.

And it was snowing when I pulled it out lol.

mjohnson · « **Reply #16 on:** January 05, 2009, 11:08:46 AM »

ok, so there is no boost. If I hit it just right there may be 3 psi, haha. Coolant was low (not surprised since it was drained for the swap). It burnt up about 1.5qt of oil. I opened up the exhaust cut out and all the oil turned in to sludge over night. Kinda cool to watch, yet depressing at the same time

Oh wait, I don't have pics, it didn't happen.

Compression test results:
1-180
2-180 note-white smoke was coming from this cylinder when I pulled the plug
3-177
4-182

by the book its plenty good.

Before the test I warmed the motor. There was a nice big cloud for about a minute then the oil from last night burned up (or flowed out, haha) after that there wasn't very much smoke until I put it under minimal load going up the street.

mjohnson · « **Reply #17 on:** January 05, 2009, 11:10:40 AM »

I'm convinced its the turbo...yet again

Jesus · « **Reply #18 on:** January 05, 2009, 11:25:53 AM »

It's the turbo.

"IF" there was that much oil entering the combustion chamber the engine would be missfiring by now... which I'm assuming it's not.

Start pulling the turbo

/thread

mjohnson · « **Reply #19 on:** January 05, 2009, 11:36:26 AM »

When there was the loss of power last night before it died it missfired and the plugs were blackened but dry. It hasn't missfired since then.

oliver · « **Reply #20 on:** January 05, 2009, 11:39:04 AM »

Compression is ok so I'm guessing It's the turbo,... You'll get smoke back up the cylinder because of the exhaust overlap.

mjohnson · « **Reply #21 on:** January 05, 2009, 11:52:03 AM »

I sent an email to the company so we'll see what they say. It says on their page that they offer 1 year warrany no questions asked...

SwiftMKIII · « **Reply #22 on:** January 05, 2009, 06:39:18 PM »

Quote from: mjohnson on January 05, 2009, 11:52:03 AM

I sent an email to the company so we'll see what they say. It says on their page that they offer 1 year warrany no questions asked...

Wishing you the best on this one...

Smokestack · « **Reply #23 on:** January 05, 2009, 07:04:42 PM »

Quote from: mjohnson on January 05, 2009, 11:08:46 AM

ok, so there is no boost. If I hit it just right there may be 3 psi, haha. Coolant was low (not surprised since it was drained for the swap). It burnt up about 1.5qt of oil. I opened up the exhaust cut out and all the oil turned in to sludge over night. Kinda cool to watch, yet depressing at the same time Oh wait, I don't have pics, it didn't happen.

Compression test results:
1-180
2-180 note-white smoke was coming from this cylinder when I pulled the plug
3-177
4-182

by the book its plenty good.

Before the test I warmed the motor. There was a nice big cloud for about a minute then the oil from last night burned up (or flowed out, haha) after that there wasn't very much smoke until I put it under minimal load going up the street.

If a seal blew on the intake side it could be giving enough oil through the intake track to give it a "wet" test. Doesn't sound like it had enough boost to crack a ring but if enough oil got into the combustion chamber it could hydrolock it. I had this happen on a turbo mustang once.

mjohnson · « **Reply #24 on:** January 09, 2009, 11:15:07 AM »

ok, so I finally got a hold of them on the phone, and the dude was asking me for the oil return line size and if I have an oil restrictor plate. He said if I didn't install it with a restrictor plate then the pressure would have been to much for the seals and would cause them to blow. He then said if that is the reason they won't replace it under warranty because of an incorrect install...I'm about to shoot this dude in the face

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