issue finding what caused turbo to fail

[Jordo_123]

hi and thanks for taking the time to read this,
i changed a friends 2011 transit 2.2 turbo (turbo is not electronically controlled) changed the feed and return as stated by the turbo manufacturer along with fresh oil and filter also cleaned all intake piping and intercooler. the old turbo oil seals had gone and was passing oil into the exhaust and intake(luckily it never ran away) my issue is after 5 month the turbo bearing has failed and was causing low to no power and smoking like it did the first time. My issue is i dont want to put another turbo on without figuring out why it failed the second time. after inspecting it after the new turbo failed i have noticed:
1. oil leak from rocker cover
2. has a fault code for intake cam position sensor ( he has been complaing of a hot start issue recently could be this)
3. when i removed the sump to inspect the pick-up it is clean but there are a handfull of small shards about 1-2mm i cant tell where its came from maybe the turbo bearing as when i cleaned the return pipe there was a couple more bits still in the pipe.

im just stuck as what to check next he did manage to drive it home when it happened and said it was only lacking in power and smoking so much he couldn't see behind himself.
i am going to change the rocker cover and while im there fit injector washers but im apprehensive about puting another turbo on when i cant find a cause to the new turbos demise.

any help in figuring out the cause would be very much appreciated. really unsure about fitting another when the 1st replacment only lasted 5 month. i have already removed the old turbo and sent it away under warranty and have been givin another one in the meantime till they decide what caused the failure

[metalworker0]

on these engines there is a filter mesh ... under the rear main bearing .. i think this feeds the turbo .. really not sure .. its made of plastic .. and goes brittle with age .. also can get blocked if oil changes neglected - think its an engine crank out to replace

some places on the net call it an oil feed turbo filter

google 1316019 transit


also smoking issues can be down to other things

hole in booster pipe
egr stuck open
turbo actuator not closing wastegate

all the best.mark

[knobby1]

on these engines there is a filter mesh ... under the rear main bearing .. i think this feeds the turbo .. really not sure .. its made of plastic .. and goes brittle with age .. also can get blocked if oil changed neglected - think its an engine crank out to replace

some places on the net call it an oil feed turbo filter

google 1316019 transit

all the best.mark

Here's the offending filter: #6C683 in the pic below, it actually goes in the front main journal oil port of the engine.

http://www.catcar.info/ford/?lang=en&l= ... EzMw%3D%3D

https://www.ebay.com.au/itm/18631041705 ... 1AEALw_wcB

Lord Knobrot (Smithy)

[Jordo_123]

on these engines there is a filter mesh ... under the rear main bearing .. i think this feeds the turbo .. really not sure .. its made of plastic .. and goes brittle with age .. also can get blocked if oil changes neglected - think its an engine crank out to replace

some places on the net call it an oil feed turbo filter

google 1316019 transit


also smoking issues can be down to other things

hole in booster pipe
egr stuck open
turbo actuator not closing wastegate

all the best.mark

i had read about a feed pipe filter but i assumed it was inside the food pipe, i hope it doesnt need one seems a big job to do. this is what i found in the sump and a few bits where in the turbo return pipe. the wastegate comes with the turbo and is preset so shouldnt be that, the turbo bearing i think is not there and it began to pass oil to the inlet aswell as destroy the impellers on the intake side from hitting the housing. i do think he had a code for egr valve but was intermittent.
https://drive.google.com/file/d/1jLRATWucKa_oMBwh1cGitRmTjEDkt-0W/view?usp=drive_link/

[metalworker0]

to see that picture ive got to go through rigmarole of confirmation by email to see it

not done


all the best.mark

[Galway]

Amature here, but I had read somewhere (probably here), that a severely blocked air intake/ filter will result in a high under pressure within air feed side on turbo, which could compromise the bearing seals leading to oil ingress (sucking oil through)..