Possible turbo issue? Engine much louder under acceleration & less go at speed

[Upex]

Another coiple of hopefully one's folks, putting the exhaust on the turbo, and putting the brassy looking micro exhaust thing that feeds egr from end of exhaust manifold, do these need exhaust sealing paste stuff on, or get fitted dry? I think paste, but want to check.

Also, the exhaust manifold gaskets, do they need to be in a particular orientation, ie where is the single longer tab? Or doesn't it matter if they only to aid removal etc?

I assume none of the turbo bolts or manifold nuts need locktight, but should any be greased with copper slip etc?

When all back together and (fingers crossed running) when new turbo primed I'm supposed to leave her tick over for 5 mins or more? If more, how long?

After she's left to idel for said period, I assume I should drive her gentle, but for how long/far? Don't want to give her the beans and it go pop!

Lastly, what mileage should I do before dropping the oil? 100 miles, more, less?

Cheers all   

[ianst0028]

NO!!!! exhaust paste is a no no anywhere near the turbo ... its ok on the exhaust after the cat bit nowhere above that
when it comes to starting it .... turn her over as we've talked about a couple of times and have a mooch around for oil leaks if its all good then start her up and let her run for 5 min on idle ..... i find a second person watching the dashboard useful here they need to keep an eye on temp and other possible warning lights
while she's idling for those 5 min your gonna be looking everywhere around for signs of oil leaks (those first 5 mins feel like 5 hours)
if that goes ok then have a brew and let her cool for a bit then let her idle for 10 min ..... during those 10 min again eyes on stalks and in the last couple of mins a fast idle ..... about 1500-2000 rpm

again check everything is ok and then comes the frightening bit ..... a small gentle test drive try not to let your @r$e chew its own way through the seat
if that all goes ok then a longer drive ....still gentle at first but towards the end of it then get closer to your normal driving style ..... if thats all ok then i'd relax and start using her as normal

oil change ..... tbh id do it after that second longer test drive but as long as you do it within the 100 miles that will be ok dont use an engine flush though 

[ianst0028]

btw ..... i know that a garage wouldnt be so thorough they'd probably do the 5 min idle and then take it for a good run but i'm a worrier so thats how i'd do it 

[Upex]

Nice one, thanks Ian.

I'll head your warnings and will do as you say. Better safe than sorry.

Picked up the oil pipes and oil filters from now, another £150 and got some acea c3 & bmw ll4 oil, plus and air filter today, so all is go for reassembly provided the weather holds. Fingers crossed.

Given you suggest changing oil far sooner than 100 miles, I'm going to order some more now, as won't have time to wait for Opie delivery.

Cheers

[RickUK]

@Upex,i really admire you taking on such a big ambitious job like this with the X5 Turbo,but it is turning into a expensive job just on parts on its own,albeit labour costs dont come into play but did you take this all into account when you decided to do the job yourself ??

Just made a quick phone call to a local turbo supplier ie Baldock Turbo services and asked them how much they would charge for a replacement turbo and also fitting as well with all the oil and filters changed and a 12000 mile warranty for £800,thats drive it into them and a pick it up price as well.Which if i am honest i thought was a very very good price.

[Upex]

Rick, had my garage had quoted £800 I'd likely have done it. Because it was near as dam it to the £1,000 Mark, it made me hesitate and decide to have a look for myself given the cheap cost of turbos.

I didn't do a full price work up as didn't realise just what was involved before I was committed.

I'll list prices and costs thus far when home, but think I'm likely near the £800 figure! However this includes much more than garage would have done, after all, how can then not charge for labour?

Will detail later, but it's important to not under value the experience and learning I've also got....

[ianst0028]

Gotta agree that your doing a shed load more than the garage would do
If the garage did the same little things that your doing I'd expect your bill to be over the £1250 mark.... Plus the vat 

[Upex]

So, rough prices thus far and indication of which I think would have been included within garage costs (not based on much other than cost vs effort and a quick call to try to get me to part with the cash):

Turbo, gaskets, £190, included.
Turbo feed pipe, copper washers, gasket, £50, doubtful it'd be included at the cost buy may of been.
Turbo return pipe, gasket, £50, excluded.
Iron manifold, £65, excluded.
Turbo to cooler (turbo side) seal, £15, included.
3 x other cooler seals, £25, excluded.
Intercooler clean, £10, excluded.
Ram air seals (airfilter to turbo pipe), £20, excluded.
Egr clean and seal, £0, excluded.
Intake manifold clean and seals, £18, excluded.
Intake manifold leak test, £0.20, excluded.
Air filter, £25, doubtful included but perhaps.
1st oil change and filter, £75, included although spec and quality different.
2nd oil change and filter, £75, excluded.
Vac pipe (all of it bar bits going into bottom of suspension - what the heck are those for?), £12, excluded.
Vac system pressure test, £25 (I bought a hand pump pressure test thing, otherwise free), excluded.
Various tool bits (that didn't already have), £50, excluded.
Dimples magnetic drain plug, £25, excluded.
Knowledge it's been done 'well', priceless, excluded.
Getting dirty, increased knowledge and likely cost savings in future due to having more experience/confidence, priceless (if this works), excluded.

These are from memory, will review recipes and correct as needed later.

[RickUK]

@Upex,sorry if it seemed that i have hijacked your thread,rest assured it was not meant to be like that,i was a little concerned that both our X5's are about the same age,as these days my spanner using days are well behind me,so basically i was slightly concerned that it could possibly cost a massive fortune at some time in the future.

Hence why i phoned up my local turbo center who done some work on a Isuzu Topper diesel about 20 years ago,they basically reduce the rpm time that the turbo cut in as i use to tow a caravan and the turbo would come in bang on time at 1900 rpm but the reduced this down to about 12-1300 if i recall,so i did not have a turbo lag with a big caravan behind me,and it worked a treat.

But they did offer basically 2 option this afternoon when i phoned them although i never told them the X5 had no troubles though,1st option they would remove and strip the original X5 Turbo and have a high probability of repairing what ever was wrong with the original one and rebuild it accordingly and re-install it.and the cost would be about the £5-600 mark or a total refurbished one which would basically be as new as what you can get for £800.

But this is the difference and please note i am not knocking anything that you are doing,as mentioned before i am admiring your job that you are doing,but what i am saying is that your turbo charger will still be the same prior to you starting work on it and it could go at anytime soon that is what i was trying too put across.

Once again i take my hat off to you and cannot wait to hear you say that its firing on all cylinders as it should do,have a great weekend.

[Upex]

Rick, your not hijacking, in my book anyway so no apologies needed. If it weren't for folks helping thus far, I'd not have a clue lol.

Regards your last post, I'm afraid I don't follow.

If the turbo was failing, replacing with a new turbo will cure it surely? Can't see how replacing the duff part will mean I'm in the same position?

When I have a flat tyre, a new one fixes it, when a suspension strut let's go, a new one fixes it.

Confused.com 

[RickUK]

I am totally lost myself,probably been a long day  ) anyway at least you are getting on top of the job and it will soon be over and finished,time to crack open a few cans and chill out 

[Upex]

On the beer, but soon finished... maybe a little optimistic.  ::)

Knowing my luck, the turbo won't be the issue and she'll be the same as she was before. Hey ho, guess we'll see, hopefully tomorrow!

Does anyone know torque specs for the oil hose (feed and return) bolts on the turbo?

Thanks

[Upex]

Well, all is back in place and test drive done, but although not as noisy she still hasn't got the punch she used to have, quite flat acceleration.

Anyone any ideas on what else could be causing the loss of power?

Not sure the new turbo is good mind, there was a bit of play in spindle before fitting, this look ok?

https://youtu.be/8u5GhLRlVDE

I think the blades may be catching the casing, as when pushing moderately there seems to be a grinding type noise!!! But may be my paranoia

Not a happy chappy  :'(

[RickUK]

A total long shot for sure,but could movement in i assume the bearing/s be like that as the turbo can get upto some tremendous temperatures so possible the play could be taken up when hot,of course could be a problem.

When i was looking at a Shogun before i bought my X5 it had just had a brand new turbo put on the car a few days prior and it had the comment that the engine revs are not advisable to go over 2500rpm for the 1st 500 miles other wise the warranty would be void i assume that this is too bed the turbo in and then after the running in period you can then use full power.

Just a thought of course,of course its worrying but give it a few days and see if it improves.

[Upex]

Perhaps. Will give it the commute this week and see what happens but there is definitely lack of boost, although my cheapo wifi dongle said boost was upto 16psi during the second test drive.

I think there may be something else wrong, but not a clue what!