Turbo Problems? Get Turbo Expert Help Now!

Hello.

I'm currently finishing up my engine conversion in my VW T3 bus, and some time ago I got and installed a larger turbocharger from a 1.9 TDI PD engine.
During the first test drive, I noticed a significant amount of smoke coming from the exhaust, and oil was leaking from the exhaust flange. Additionally, the FLEX pipe was heavily saturated with oil and was also leaking.

Well, I thought the turbo wasn't expensive.

Okay, so I bought a new one. The seller told me it had only 68,000 km and was in top condition. I bought it, installed it, and it was still smoking. Well, I thought, maybe there's a lot of oil in the pipe and exhaust, and it will burn off eventually. But, sure enough, the FLEX pipe is soaked again, and it smells strongly of burning and is smoking.

Have I been cheated? Could the new pump also be broken, or are there other reasons why it's leaking oil?

Could the return line be blocked, causing the oil to find an alternative route? Although... the hose is new, it goes directly into the oil pan and gets hot, so oil must be flowing through it.

When I rev the engine while it's idling, it doesn't smoke as much as it does when it's under load.

And with the engine and the original AFN turbocharger, I took the old van for the emissions test, and everything was fine; it didn't produce any smoke.

I would really appreciate any help; I finally want to be able to ride the bus.

Thank you and best regards.

Toto.

Hello.

Based on your description, the turbocharger might already be faulty. It would make sense that it doesn't produce any smoke when idling and being revved up, as there is no boost pressure being generated.
Being tricked twice would be quite something...
Did you perhaps make a mistake during the assembly? For example, did you forget to fill the turbo with oil at the inlet before screwing on the oil supply line? A blockage in the return line is also possible. You say that oil is coming through, but is it enough?

Best regards!

I have to admit: No, I didn't fill the turbo beforehand!
But the oil pressure should be present immediately after starting the engine, shouldn't it?

Could it really be that I was killed by that charger...? I can't even think about it...

At the very least, all the instructions state:

Before installing the oil feed line to the turbocharger, fill the turbocharger's inlet port with engine oil.

It seems like there might be something to it (I'm not saying this to be sarcastic; I haven't experienced it myself before).
considered as soooo important... definitely absolutely makes sense, but the fact that the turbo immediately fails ).

Best regards,
Rudi

Hi,

Here's a tip for lazy people like me: After installing a turbocharger, let it idle for 20 seconds with the wastegate disconnected or the power delivery lines removed.
Then it's definitely important to ensure that oil is being pumped all the way up to the turbo.

Best regards, Rainer.

I think I've found the solution: I believe it was the return line, which had a 10mm diameter at the loader, and the fitting on the oil pan was only 6mm.

I had a new hose made, and now it's not leaking anywhere.

Then you can now also mount the large PD charger again .

After replacing the turbocharger, the engine should definitely be started using the starter motor and with the fuel cut-off activated for at least 20 seconds, as Rainer already mentioned. The turbocharger will start spinning even at idle speed after being started. It's important to ensure that it receives sufficient oil during this process.

Greetings, Uwe.