Am I having my pants pulled down?

[kickin_chicken]

As some of you may have read the turbo blew on my 2002 Transit 2.4 TDDI RWD last Sunday causing the engine to runaway but I think or thought I managed to catch it but stalling it, well I've finally fitted the replacement turbo but there is a distinct lack of power and a thumping noise coming through the intercooler - inlet manifold pipe, when I rev the truck this pipe sucks shut, which to me would explain why there is a lack of power but I don't know why there's such a strong vacuum unless the engine is knackered.

I took the truck to a transit breakers the guy there listened for about 10 seconds and said "you're chain has stretched mate" now I thought I would've heard a rattle if the chain had stretched, prehaps not, he said he could supply and fit a chain for £350 but then the head might be knackered which would cost X amount for a reconditioned head, they then offered a replacement engine for £1000 plus VAT with a 3 month warranty.

Now some of you may say why spend that much on a 2002 Transit, well it's a recovery truck in pretty good nick with hardly any rust and a decent bed plus I've spent money on having it remapped and uprated the springs on the back and 12 months MOT 2 weeks ago.

Basically what I'd like to know is would you hear if a chain is stretched (no rattling when starting from cold or when running cold or warm) and what would you think is causing the vacuum to collapse the inlet pipe.

Any help would be gratefully appreciated before I spend £1200 on a replacement engine.

Cheers

[mrrcarney]

this sounds more like a blocked intake at some point try the following

1. air filter remove and test (hover airbox out so no leaves etc end up in your new turbo)
if no better
2. inter cooler is blocked or filled with oil restricting flow get it off and flush it out

I have previously had a similar issue this is two easy free tests !

if you have a bit of pipe about two and a half feet long about 3 inch diameter (drain/gutter) just bypass the inter cooler and test
if this solves the issue pull the inter cooler off and rinse it out into a bucket then spray or pour some brake cleaner down it to help get rid of oil/water mixture

hope this helps

cheers rob

[kickin_chicken]

Hi Rob

Thanks for the reply, I'd taken the intercooler off and gave it my wife to clean out with petrol (because I'm nice like that lol)

But I'll take it off again and have another go also try your suggestion of a replacement pipe in place of the intercooler. I'll also remove the air filter and clean.

If it turns out to be a blocked intercooler I'll be very annoyed with the transit breakers.

[mrrcarney]

I have had an air filter so badly soaked in oil after turbo failure that I had a non start issue
that's why I am suggesting just remove it and test

cheers

[kickin_chicken]

Just finished checking over the air filter it was bone dry

Tried a pipe in place of the intercooler and the same thumping/sucking shut of the inlet manifold/intercooler pipe.

I'm beginning to think I need to fork out a lot of cash to sort this out

[mjsroofing]

I'd be very interested in knowing the results for this one.

[mjsroofing]

There's got to be a blockage in the air intake somewhere.
Have tried running it with out intercooler pipe on.

Was there any kind of protective cap on the turbo when you bought it.
What about the actuator valve, could be stuck shut/seized.

[kickin_chicken]

No protective cap on the turbo it was a used unit from NLC spares (Transit breakers)

It seemed to spin freely with no play i also checked the actuator rod by hand which moved as it should.

I have removed the intercooler pipe from the EGR valve and the thumping sound was quite loud also a large vacuum into the EGR valve.

I remember when I cleaned and blanked the EGR valve and inlet manifold (about 6 weeks ago) I forgot to tighten the jubilee clip on the EGR/Pipe I pulled off the drive and the pipe came off I could hear the loud thumping sound then, but the sound went away when I refitted the pipe.

Could a bent valve or something more serious with the pistons cause a large vacuum from the engine side? The one thing I didn't clean out when fitting the replacement turbo was the EGR valve and inlet manifold, possibly a job for tomorrow if the weather holds out.

[mjsroofing]

When you take the inlet pipe off there is a massive vacum , will suck your hand in easy, so if the pipe is collapsing it must mean that there is a blockage of some sort.

Something isn't right, it's not letting enough air through.

Maybe remove and check pipes, blow through them maybe., with pipes off, blow through from air filter box side,

[kickin_chicken]

Thats good that the vacuum should be there I'll be taking all the pipes off again tomorrow. only the intercooler - EGR pipe is collapsing which would suggest a blockage in the intercooler but placed a bypass pipe in and it was still collapsing. The other pipes seem ok. Could it be a dud turbo?

[mrrcarney]

as above this is a blocked pipe remove the turbo to air box pipe

if still no better remove the turbo/inter cooler pipe and check for blockage

all these 2.4 tddis make a thump thump thump sound when you remove the pipe from egr well the two that I have owned and all that I have worked on did

but its got a breathing problem the engine is trying to suck in the air and something is causing a bottle neck so its sucking the pipes closed

cheers

rob

[mjsroofing]

Thats good that the vacuum should be there I'll be taking all the pipes off again tomorrow. only the intercooler - EGR pipe is collapsing which would suggest a blockage in the intercooler but placed a bypass pipe in and it was still collapsing. The other pipes seem ok. Could it be a dud turbo?

Could be blocked anywhere between the pipe that collapses and the air filter.
Air should pass the turbo even if it don't turn.

[kickin_chicken]

Thanks for the advice guys it really is appreciated I'll check all pipe work tomorrow and post back my findings

[dieseldel]

hi
my thoughts are the turbo is not spooling up. as the intercooler pipes are collapsing the turbo is not creating any pressure, put the pipes back on and rev the engine and check BOTH intercooler pipes, the pipes should swell with pressure produced by turbo my guess would be that both pipes don't harden or swell ie no boost pressure, if the pipe FROM turbo swells and the pipe AFTER intercooler doesn't then the intercooler is blocked as per previous posts. good luck.

[Frag]

If with engine running,you unclip and lift lid on airbox,
and have the 'thumping' noise you describe......
That indicates a valve/train issue..........

Hoses sucking flat shouldn't be hard to diag as obviously anything after turbo to inlet should be under pressure from boost....