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]

yes but it jamms SHUT too ....

yes but it jamms SHUT too ....

 

can you show that, as that's what you need to demonstrate to get any further.

couldn't replicate it on the bench it only seen and wouldn't move when i pulled the engine out

Did TD come back to you with their findings mate?

Good luck in getting it back on the road and reliable tho :-)

smithy

Yep ... Spoke to them after this email ... and explained how the Intake works on the car as per this email there assuming that the Plenum intake is shared over 6 cylinders

but as its the Zed and Nissan's over designing its a Split intake system

he wants me to put in writing about the problems and how/what/if in a letter to his Boss to take forward the rebuild costs

 

 

Hi Mark,

 

Having tested the operation of both turbocharger actuators I can confirm we concur with your findings that one of the actuators (the one in your video) is indeed seizing. This is due to the poppet valve actually catching on the valve seat. This occurs due to certain amount of “slack” between the valve and the arm, allowing the poppet valve some degree of movement. In this case as the valve is closing, it drops/moves into a position where on some occasions it snags on the valve seat. This is very easily rectified by peening the valve to reduce the “slack”, and of course will be done under warranty.

 

With regards to the engine failure, we find it highly improbable that the turbochargers wastegate issue has resulted in engine failure. We have tested the mechanism repeatedly – there is no evidence the mechanism is seizing shut whatsoever. The only position the wastegate is seizing is partially open. This would result in a lack of boost pressure developing on the passenger side bank. My understanding of the balance bar is that this would then demand more from the sister turbo on drivers side (failed bank), however boost would be limited to the pressure setting of the actuator on the driver’s side turbo (which is fully functional), removing any risk of overboost in those 3 cylinders, just excessive rotor speed which would only result in turbocharger failure. With the above in mind, we do not accept the turbocharger has led to such severe overboost to have caused engine failure – if anything the fault found with the turbochargers would have led to a lack of boost pressure.

 

I am afraid we will not be reimbursing you for any costs related to the engine failure.

 

Fortunately both turbochargers are fit for re-use. We were expecting some damage to inducer blades of the turbine wheel on the failed engine side, however any piston/valve that has made its way to the turbocharger has done little to no damage. The driver’s side turbo is leaking oil due as a result of the engine failure, but does not appear to have damaged the turbocharger in any way.

 

We can repair the wastegate and clean the turbochargers under warranty, at no charge of course. Please advise if you would like us to proceed with the turbochargers and get them returned.

 

Kind regards,

I think TD have been very understanding and the repair of the turbos under warranty is very good of them albeit what the warranty is there for. As for them picking up the cost of a engine rebuild i would say highly unlikely. There is various factors that they can use if legal proceedings were introduced and i hope their name is not tarnished in this pursuit having used them myself before.

Edited July 20, 201213 yr by Gonzo12c

whos tarnishing there name ? every thing that's been posted and said and replied to is Fact and truth

I was speaking in future tense as i can see where this would lead when you dont get the answer you are hoping for

i'm a little more grown up than that ..... and i know what forums can do for Biz ... after all i do run my own biz ...

Have you looked at other parts that could cause a piston fry. Injector, tuning and so on. It is easy enough to find a problem and assume this caused everything however if you do rebuild this engine and use the same parts then it would not be good to get exactly the same fault later on down the line. From what i remember you had boosting issues and suspected the BC was at fault well i think you have found what was causing that fault. As for piston fry i would have a serious look and test of other components to see where best to spend your money on.

Edited July 20, 201213 yr by Gonzo12c

understand what u have said but all the other items that would make it Run Lean to give the same fault is brand new ... but damage is only on one bank ...

if it was down to tuning .. as you said this would effect the the last cylinders in line on the fuel rail mainly ... well thats on the opersit side

 

i will get the injectors tested but i'm sure JD's tuning chip is Spot on :)

Sorry to hear this Mark. I am pleased that TD has honoured their obligations regarding the turbo warranties; and I hope you can get the engine issue resolved with the minimum of fuss.

 

Good luck mate,

 

Richard

I always liked TD years ago but of late the service they give is shocking,the left hand is literally unawhere of the existance of the right there not what its doing,the guys that answer the phone sound about ten years old and "have to just go and check" anything you ask constantly,Place is a Monkey Temple and to be avoided.They made a right balls up of Jaffas turbo replacement,housings clocked wrong,the actuators they fitted were inferior after they refused to reuse the existing ones.Not a place id use now.

Who would you use jimmer?

I'm confused now

 

how is this different to pointing out the costly failings and bad experiences of dealing with Ztech or Severnside Imports?