as you all know i just rebuilt my engine with forged parts and all was good for 1k ...

then i started to have a problem with my boost controller so i thought ... ha well

 

looks like i gonna have to rebuild my fooking engine again due to my bloody turbo act sticking

these was even tested at TD just to make sure they was ok ... came back with a good bill of health

 

be sure i will be taking this up with the company i got them from as there under warranties

 

well check the video out

 

and yes i said Pistons ... not valves :)

 

[video=youtube_share;8hB3JPeFgi8]

totally gutted for you mate.. all the best of luck getting them to to put this right for you....

sorry so basically the turbo actuator has remained jammed allowing the turbo to overboost? and melt the piston crown? i bet your sick of that bloody engine now anrt you? i suppose if they teste dthem and certified them and its cause dthe damge could you potentially forward to cost to them of the rebuild? if your coming back down to turbo technics which i beleive isnt far from me? in dorset. give me a shout you can pop in for a brew if you want mate.

Yeah ...

 

Need to have

New Valves & Recut in

New Head Gasket as that is damaged ( comtec )

3 New Pistons and Rings

 

Looking about £550 in parts plus another £40 to sort Head

Edited July 14, 201213 yr by MarkDerby

i would be pissed

what a blow :( no wonder you're pissed off!

did the overboost redisture (or however you spell it) or because of the fact it was only on one bank did it not show very clearly.

"sorry so basically the turbo actuator has remained jammed allowing the turbo to overboost? and melt the piston crown? i bet your sick of that bloody engine now anrt you? i suppose if they teste dthem and certified them and its cause dthe damge could you potentially forward to cost to them of the rebuild? if your coming back down to turbo technics which i beleive isnt far from me? in dorset. give me a shout you can pop in for a brew if you want mate. "

 

Yeah thats right its been over boosting one side of the engine ... with the balace bar being kinda small this would cope with about 2>5% imbalance but not at all most 80% so inturn this has make the engine Run Lean on one side ...

nothing to do with tuning as AFR was spot on 12>11 on full boost

 

and yes its Turbo Dynamics ...

all so when i had them back from testing one of there staff told me there was a Problem ... the TESTER had dropped a turbo and parts had been replaced ... what one i dont know due to them being very new they both was clean and looked right

 

it never did this before and i suspect its that tub

 

And yeah i'm really pissed off now

Mark so are you saying the wastegate was sticking open mostly? because that will not cause overboost or was it sticking in both ways, did you not notice a reduction in boost when its stuck open?

 

We had a sticking wastegate on a standard turbo`s once but with low boost occassionaly as it was sticking open and was a badly set pivot pin and a poor quality valve, the turbo had been rebuild at some time and the issue had been since the rebuild so turbo companies do get it wrong sometimes.

 

Bad luck though either way.

 

Jeff

well thats what i was trying to explain to you ... even tho it was sticking open it would still boost ( as normal ) 16psi ... it was the other turbo compensating

hence one half of the engine as ran lean

i hope they help you out, but if they didnt carry out the work fitting it to the car, you can bet they'll leave you in the poo. so gutted for you man! fingers crossed!!

That sucks big time Mark,, after all your hard work getting it finished in time aswell. Give the barstweards hell when you get to talk to them. Hope it works out for you in the long run

that doesnt sound right to me with the wastegate open you are gonna lose a whole load of boost

Yep on one side so the other turbo is making up for lost boost ... In turn runs lean on one side

Balance bar will not do its job with that much of a diffrence

What a fookin shitter Mark!!!! I really hope they sort it for you mate, all that time,money and effort, its not fair!! but knowing you, you will be soon back up and running again ;)

what was the damage? If the actuator was stuck half way I could see 2 things happening

 

1) slow spooling

2) over boosting, but looks like it was still opening fully when needed, just not closing affterwards so this shouldn't happen.

 

As each turbo feeds the other bank, you shouldn't get into the position of one turbo doing more than the other. That's why stock cars with one blown turbo get no positive boost. Unless you have a FMIC which doesn't feed the opposite bank? This could lead to one side doing more work than the other.

 

Are you measuring AFR on both banks?

 

PS I have some spare pistons, which size are you looking for?

Just seen part of the vid theres not alot i can say would quite easily be picked up on testing or has happened when fitted due to some other reason.

Have you spoke to them yet Mark, what's the verdict?

Read from the bottem up

 

 

 

 

Hi Tom

Ok the turbos each side of the engine feed only 3cyl per side on a sepret plenum chamber Linked with a 1” balance bar if one tub starts to play up the boost demand is still there

But at the link bar will not flow the amount needed it will make the engine Run lean or Boost way to much on the side that is working correctly but then Over working to provide the Lack of been

 

 

“on a twin turbo, if one goes down, the other one will speed up to compensate for the drop in pressure. They're linked through a boost controller that will just keep both actuators closed until it sees the right pressure. When you have one turbo speed up you end up with a plenum at very high boost as is expected when you have two plenums fed independently by two seperate turbos”

 

 

-------------------------------------------------------------------------------------------------------------------------

 

 

Hi Mark,

 

I am not sure I understand the last part of your email, but the if this valve is catching on the valve seat, heat and expansion will not cause it to seize shut, it will only increase the problem of it seizing open. If it is seizing shut, it is not due to the valve catching.

 

Regards,

 

Tom Russell

 

-------------------------------------------------------------------------------------------------------------------------

 

Hi Tom

 

In the video only shows the tub sticking open but when it was bolted to the engine and i tested it in front of my Tech guy it jammed shut a few times

Lets say when car/turbo is hot that it gets worse and does Jam shut/open more think u will find its the route of the Problem just happend

 

Will let u know soon as there Packed ready to go

 

-------------------------------------------------------------------------------------------------------------------------

 

Hi Mark,

 

I certainly agree there is a fault with the turbocharger, this is clear in your video. This of course will be sorted under warranty assuming our initial diagnosis is correct.

 

I understand what you are saying about the failed engine bank being on the same side as the faulty turbo, but assuming the valve is seizing open its physically impossible for excessive boost pressure to be delivered to that side of the engine.

 

Let me know which day you would like me to arrange the courier for and I will make sure it is done.

 

Regards,

 

Tom Russell

 

-------------------------------------------------------------------------------------------------------------------------

Hi Tom

 

Yes once i find a box for them i can get them packed as arranged.. remember one turbo works one half of the engine and other tub other half

This turbo at fault as the same side of the engine has failed on

The turbo is at fault and it needs sorting out

 

Mark

 

-------------------------------------------------------------------------------------------------------------------------

 

Hi Mark,

 

Judging by the video it appears to be seizing after full extension, when pressure is released and the valve tries to close. This can occur (although it’s very uncommon) when the poppet valve has too much “play” and when fully extended, then released, the valve picks up on the valve seat, causing the valve to stick open – the video you have attached appears to show this as the problem (we can confirm for sure once the turbos are back). This can be rectified by modifying the valve/mechanism to remove this excess movement – it’s a simple procedure.

 

This problem, as per your video, only occurs when closing the wastegate, thus seizing the mechanism open. In your video it doesn’t appear to seize shut at any point (if the valve is catching on the valve seat, it cannot seize shut). This would have the opposite effect to that you have described as the engine failure. The only impact this would have on the engine would be a lack of boost pressure as the wastegate is open – this could not possibly result in such an engine failure.

 

Would you like me to arrange a courier to come and collect the turbochargers? We can then confirm the fault with the turbocharger and proceed accordingly.

 

Kind regards,

 

- - - Updated - - -

 

trying to riddle out of it if u ask me ....

Oh Shit!!

 

Only just seen this. That's terrible mARK. Hope you get it sorted soon.

 

Andy

Sounds like theyre building up to get themselves out the shit to me.

Mark, don't mean to be devil's advocate, but what tom is saying is correct. Can you describe symptoms before failure and what's damaged? Do you have side mount or front mount intercoolers?

front mount IC and No its not plumbed in wrong as its Autobahn/HKS

740injectors

JD tuning running @ 16psi

AFR on boost 12>11 ( slightly on Rich side )

No boost leaks tested up to 25psi

All engine timing and sensors was fine

tested and checked 5 days before

 

 

thought i had a Problem with my boost controller as it wouldnt controlled the boost right to high or not at all then some times it was ok ... so taken it out and connected the tubs up as stock

16psi on these tubs everything ok ...

untill started to missfire and smoke out the exhaust and breathers .. as that point i knew something bad was wrong

pulled the engine out and noticed the act on tub was stuck open

Edited July 16, 201213 yr by MarkDerby

Cool, what was the damage? AFR on both banks, if not was it the same bank as the failure or opposite side

 

At least TD are happy to fix the actuators

Cool, what was the damage? AFR on both banks, if not was it the same bank as the failure or opposite side

 

At least TD are happy to fix the actuators

 

Passanger tub ... drivers side bank cyl 123 AFR seemed spot on

 

Damage is

Cyl3 Melted piston and 4 valves

cyl 1/2 pitted piston

burnt head gasket

 

cly 456 like the day i put them in there

I say i have to agree with what he has said and do not see how you come to your conclusion that a valve stuck open is going to create over boosting and therefore a lean mix. You will effectively be creating pretty much nil positive pressure on one side so the engine would run ragged and one turbo wouldnt be enough to create excess boost. Even then the pressure would be dumped as its still protected from overboosting by the actuator. I think for the problem to occur so quickly after rebuilding there is something else at fault either as well or first.

 

I think the turbo company are pretty much not going to pay out as well due to them presenting an argument against your claims. Times like this some kind of warranty comes good. Its harsh but thats life.