E46 320D Dreaded Turbo Failure

[rgrotz]

Hi all, I'm a newbie to this site, have acquired my first BMW, a 2005 E46 320D recently (76 000km).
Having read through all the turbo woes, I decided to undertake some preventative maintenance. Removed & cleaned the EGR & intake manifold, replaced crank breather with new vortex style and removed the swirl flaps (1 on it's way out...) and replaced vacuum pipes. Re-assembled and all was running beautifully until a couple of km's later, exactly what I was trying to prevent, happened...a plume of white smoke from exhaust, high pitched shrieking noise (turbo I presume) and no power. Stopped immediately and towed it home...
Stripped engine again to find oil everywhere (intercooler pipes, turbo, exhaust, cat, manifold and head). My question is this - the turbo blades appear intact (no physical object caused damage), do you think that because the turbo was so accustomed to oil starvation due to blocked breather, the sudden high pressure resulted in oil seal damage? By removing and flushing out all the oil, and replacing/rebuilding the turbo, is there anything else I should be aware of? Any tips, suggestions or similar experiences would be highly appreciated. Also, where's a good place to find used spared for these models (diesel E46's) in Gauteng?
Appreciated, Richard

 

[P1000]

Call Engineparts for the turbo, they have the best prices and are the importers. Do not try to rebuild a VNT turbo, its not worth the risk, Garrett has a whole article on why. Your procedure sounds good, just be sure to prime the turbo, a second on a turbo without oil is like an hour on an engine without oil...

I think the turbo most likely failed because of coked oil burning onto the shaft and then eating away the bearings. It is what happens if you don't let it cool after a hard drive.

 

[rgrotz]

Call Engineparts for the turbo, they have the best prices and are the importers. Do not try to rebuild a VNT turbo, its not worth the risk, Garrett has a whole article on why. Your procedure sounds good, just be sure to prime the turbo, a second on a turbo without oil is like an hour on an engine without oil...

I think the turbo most likely failed because of coked oil burning onto the shaft and then eating away the bearings. It is what happens if you don't let it cool after a hard drive.

Thanks for the rapid response & valuable advice, re: rebuild vs new & turbo priming. Will give Engineparts a call...

 

[rgrotz]

Just a quick update - phoned Engineparts but unfortunately they don't have stock until Feb '11...Turbo Direct have the same Garrett turbos for a similar price (+-R8500 exc). I may risk trying a rebuild as my cash flow is limited. Turbo Direct will charge R1800 exc to install kit and balance etc. I'll keep you updated about lifespan, if the rebuild is possible (no rotor,compressor damage etc). Ciao R

 

[P1000]

Keep us updated + post lots of pics.

Here is the article:
http://www.turbo.com.sg/e-news/Garrett VNT - Non-repair buletin.pdf

 

[rgrotz]

Eish! I see what you mean...perhaps should rather wait for the bucks to replace it. Thanks again for your efforts.
Will send pics asap.

 

[rgrotz]

Keep us updated + post lots of pics.

Here is the article:
http://www.turbo.com.sg/e-news/Garrett VNT - Non-repair buletin.pdf

Just an update - have removed the cat insides & rewelded box, cleaned out the oil in the inlet manifold, intercooler etc. Turbo now redone by Gaby at Turbo Direct for R1850 (fortunately no damage to shaft etc, so only repair kit and balance required). He did mention that overheating was definitely an issue and that he has heard of similar issues once the crank breather is changed - although a new part installed, it may not be functioning properly. Do you know how the vortex breather should work and how I can test the operation and whether it was installed properly?
Also oil pump change recommended by many turbo guys - is this absolutely necessary?

Many thanks
Richard

 

[P1000]

I would replace the oil feed line and check the oil return line for blockages... I believe the oil pump change might be more difficult than it seems... I don't know how the new breather could have caused this :thinking:

 

[rgrotz]

Ok thanks - will replace and clean the lines, replace oil & filter, put in the turbo (prime) and hold thumbs...
Everything that possibly can be done in the way of preventative maintenance is now done, so hopefully it will run ok. :drama:

Thanks for all your advice.

 

[P1000]

Out of interest, what oil did she have in when the failure occurred?

 

[rgrotz]

Not sure - just purchased the car from a seller in PE who has serviced her at their regular "shop" for the past 3 services.
The vehicle had done only about 2000km after the 75000km service. What oil would you recommend, as I have just drained it? Planning on using Castrol Edge fully Synthetic 5W30.

 

[P1000]

That will work. I use the same, but 5w40. Now At 272kkm on original turbo (but its a 530d)

 

[rgrotz]

That's exceptional - do these have the same swirl flap/egr/breather issues?
Thanks again. Once I learn how to post pictures, I will be sure to put some up...

 

[P1000]

Jip, but my egr is disconnected and swirl flaps were replaced with blanks at 267kkm. (The car was a highway car... did 80kkm in year 1 between bloem and jhb)

open a photobucket account, put the pictures on it, and copy the img code to your post, easy as pie.

 

[rgrotz]

Cool, will do...