GTK-450 Leak Problem

Doctor · Tweet this Post! #1 (**permalink**) 02-18-2010, 02:33 PM

Hello from Greece.

My name is Mike, and for the last month we were building a BT Audi A4

My Track-Spec A4 B7 Project

I have used a brand new Turbonetics GTK-450, bought from US dealer, and have been running it for two weeks or so not more than a 1000kms...
since the beginning, i had some issues with a leak from the bolts at the hot side of the turbo, at the back of it...at first a bolt went loose...then I tightened all of them, they didnt come loose again...then i had some more leak...when i wiped it it was black i thought it was gas going off the flange...
But then it continued leaking from time to time, and smoke was produced from the turbo being hot burning the leak's fluid...
Wiping it out today, i saw it was propably oil...But no oil smoke at the exhaust as fas as i know...no smell from the exhaust either...just the leak, once from the upper bolt, once from the deep down under one...
And then i tested the car some more at a trip i made...with normal driving and some pulls...nothing more than the ordinary...
and then i saw this happening...

What you cannot see from a photo, is the lowest one of the hot side's 6 bolts, at the back of the turbo is full with oil, and the leak is obviously from the turbo...

My questions:

1. Turbonetics clearly states there is no reason for an oil feed restrictor so i havent used any. what is more i am afraid to use one, so as not to destroy the turbo from oil starvation.

2. could the leak be caused due to increased crank pressure because of me not running an oil catch tank, and just putting a small filter here instead of the oil catch tank...?

In addition to that, we also suspected of high crank pressure because the engine's cover seems to leak some oil whereas it didnt use to in the past...But could it be so much, to cause the turbo to leak as well...?

3. could the leak be because of a need to rotate the turbo's cartridge to a more vertical position...?

Just thoughts....give me your help please...

PS: Car's oil level obviously went low, and my oil press gauge was running normal.

Thanks in advance for your help...

Mike

Robert · Tweet this Post! #2 (**permalink**) 02-18-2010, 02:54 PM

Quote:

Originally Posted by Doctor

Hello from Greece.

My name is Mike, and for the last month we were building a BT Audi A4

My Track-Spec A4 B7 Project

I have used a brand new Turbonetics GTK-450, bought from US dealer, and have been running it for two weeks or so not more than a 1000kms...
since the beginning, i had some issues with a leak from the bolts at the hot side of the turbo, at the back of it...at first a bolt went loose...then I tightened all of them, they didnt come loose again...then i had some more leak...when i wiped it it was black i thought it was gas going off the flange...
But then it continued leaking from time to time, and smoke was produced from the turbo being hot burning the leak's fluid...
Wiping it out today, i saw it was propably oil...But no oil smoke at the exhaust as fas as i know...no smell from the exhaust either...just the leak, once from the upper bolt, once from the deep down under one...
And then i tested the car some more at a trip i made...with normal driving and some pulls...nothing more than the ordinary...
and then i saw this happening...

What you cannot see from a photo, is the lowest one of the hot side's 6 bolts, at the back of the turbo is full with oil, and the leak is obviously from the turbo...

My questions:

1. Turbonetics clearly states there is no reason for an oil feed restrictor so i havent used any. what is more i am afraid to use one, so as not to destroy the turbo from oil starvation.

2. could the leak be caused due to increased crank pressure because of me not running an oil catch tank, and just putting a small filter here instead of the oil catch tank...?

In addition to that, we also suspected of high crank pressure because the engine's cover seems to leak some oil whereas it didnt use to in the past...But could it be so much, to cause the turbo to leak as well...?

3. could the leak be because of a need to rotate the turbo's cartridge to a more vertical position...?

Just thoughts....give me your help please...

PS: Car's oil level obviously went low, and my oil press gauge was running normal.

Thanks in advance for your help...

Mike

It's very possible that the cause is that you don't have enough vaccum on the engines PCV port. I would definitely start by getting that hooked correctly. I can't see the angle of the bearing housing real well from the pictures but that is something else you could check as well yes.

Doctor · Tweet this Post! #3 (**permalink**) 02-18-2010, 03:02 PM

Quote:

Originally Posted by Robert

It's very possible that the cause is that you don't have enough vaccum on the engines PCV port. I would definitely start by getting that hooked correctly. I can't see the angle of the bearing housing real well from the pictures but that is something else you could check as well yes.

Here is the angle...

http://i1000.photobucket.com/albums/...c/DSC07333.jpg
http://i1000.photobucket.com/albums/...c/DSC07426.jpg
http://i1000.photobucket.com/albums/.../Image1340.jpg
http://i1000.photobucket.com/albums/.../Image1336.jpg
http://i1000.photobucket.com/albums/...c/DSC07395.jpg

The high crank pressure in addition to the head gasket leaking is leading us towards that direction to...whereas it didnt leak in the past when running an oil catch tank...

Robert · Tweet this Post! #4 (**permalink**) 02-18-2010, 11:02 PM

Quote:

Originally Posted by Doctor

Here is the angle...

http://i1000.photobucket.com/albums/...c/DSC07333.jpg
http://i1000.photobucket.com/albums/...c/DSC07426.jpg
http://i1000.photobucket.com/albums/.../Image1340.jpg
http://i1000.photobucket.com/albums/.../Image1336.jpg
http://i1000.photobucket.com/albums/...c/DSC07395.jpg

The high crank pressure in addition to the head gasket leaking is leading us towards that direction to...whereas it didnt leak in the past when running an oil catch tank...

Just based on those pictures I have to agree. I don't see any crazy angle on the bearing housing that would cause this. Without positive crank case ventiallation (actual vacuum being drawn from the PCV port on the motor) this is almost 100% the issue.

Doctor · Tweet this Post! #5 (**permalink**) 02-19-2010, 12:20 AM

Some others claim it is a faulty turbo...some others it is the thinner oil 0w30 against the 5w40 i used before, but then there was a leak too....
Some others tell me to unbolt the downpipe and check for oil and then, the CHRA is faulty...
Some others tell me to try a restrictor...
Some others tell me the PCV system is fine this way and there is no need to do anything about it, they had been running it this way for long...

I really dont know what to do...

Robert · Tweet this Post! #6 (**permalink**) 02-19-2010, 08:31 AM

Quote:

Originally Posted by Doctor

Some others claim it is a faulty turbo...some others it is the thinner oil 0w30 against the 5w40 i used before, but then there was a leak too....
Some others tell me to unbolt the downpipe and check for oil and then, the CHRA is faulty...
Some others tell me to try a restrictor...
Some others tell me the PCV system is fine this way and there is no need to do anything about it, they had been running it this way for long...

I really dont know what to do...

Setting up the PCV system for vacuum shouldn't take a lot of work or time. I would start there. If it is the turbo and it was purchased new it will be repaired at no cost to you under the 12 month/12,000 mile warranty that is standard on all new units.

Doctor · Tweet this Post! #7 (**permalink**) 02-19-2010, 11:02 AM

Quote:

Originally Posted by Robert

Setting up the PCV system for vacuum shouldn't take a lot of work or time. I would start there. If it is the turbo and it was purchased new it will be repaired at no cost to you under the 12 month/12,000 mile warranty that is standard on all new units.

before i do that, i bought a gasket and will change the valve cover so as to eliminate the chance of the oil coming from there...If the problem continues then i will make arrangements for the turbo to be changed somehow....it was bought new from US, from an official dealer i have all invoice with me...brand new...
I think there is some leak, but of gas...from the bolts...i dont like that either...but it must not be oil...
I think some other have had gas fumes and like black powder coming out of the hot side's bolts is it not..?

Doctor · Tweet this Post! #8 (**permalink**) 02-22-2010, 12:46 PM

What is Turbonetics official policy.

Do i need to use a restrictor in the oil feed line, yes or no...?

My turbo is GTK-450, oil and water cooled., oil feel line is 4-AN

Robert · Tweet this Post! #9 (**permalink**) 02-22-2010, 12:53 PM

Quote:

Originally Posted by Doctor

What is Turbonetics official policy.

Do i need to use a restrictor in the oil feed line, yes or no...?

My turbo is GTK-450, oil and water cooled., oil feel line is 4-AN

Unless you have ridiculously high oil pressure no. By ridiculous I mean 80 PSI at idle.

Doctor · Tweet this Post! #10 (**permalink**) 02-22-2010, 01:32 PM

Quote:

Originally Posted by Robert

Unless you have ridiculously high oil pressure no. By ridiculous I mean 80 PSI at idle.

I have about 30psi at idle, and not more than 60 psi at wot, reaching a maximum of 90psi which happens when the car starts usually, and i can see it from the oil press gauge's memory/peak function.

So, i guess it is a NO for an oil restrictor. Ok.