Need help with FPP rear mount turbo !!

[Motorhead]

I have been working on this sled for quite a few weekends at this point, hoping to put it away for the season and start on this project again in early fall. Installed stearing bearings and replaced all bushings in front end, also replaced many broken components, thus have had the sled apart in different stages for the past while. Needed to get to front steering components so intercooler and battery came off. Put it back together this weekend and thought I would start it and load it in trailer for the summer to make room in my garage for bike projects. When I turned the ignition on I noticed that the aux oil pump ( quite loud) was not working and neither were my boost gauge and suspension pressure gauge LIGHTS.
Started it and it did not sound good, sounded as if it was firing on only 3 maybe, and also making a leaking exhaust noise from under intercooler some where and also spitting from intake I think.. It was running fine before I took it apart !! Anyways I found and replaced the bad electrical connector which caused the Turbo oil pump and gauge lights to misfunction.

Once done with that I noticed a couple ounces of oil on the floor under the rear mount turbo, so I stripped it down so that I could find the oil source and sure enough it was coming from the turbo air filter !!!

Question, How did the oil make it to the turbo air filter and did I screw anything up by starting it that way ? I guess it all comes apart again to clean the intercooler also, that must have gotten some oil in it also.

Are changing spark plugs in order at this point ?

 

[Motorhead]

Still in denial mode, will have to do a compression check next weekend. Can't imagine what went wrong but I am imagining the worst whereas it sounded like leaking exhaust from under the intercooler!

 

[tjc]

did you take the motor apart during all your repairs? If not I cant see how the motor would be damaged.

The return pump not working would explain the oil in the filter. The oil would blow out the turbo once the return could not keep up.

 

[mbarryracing]

Agreed 2X, the oil came from when you ran the engine without the scavenge oil pump running, so the pressurized oil pushed by the turbo center section seals... I recommend you pull everything apart now and clean all the oil out of the charge tubes...

Re-check all your electrical plugs near anything you disassembled during the tune-up, you have something loose and causing the engine to run poor ir misfire. Check all the battery cable connections at the relay block, etc.
What you had touched wont hurt the engine... something else is catywompus. That exhaust noise you hear could just be sucking air noise from an oil scavenge line from the turbo return pump or oil tank, etc might be you hooked a hose or something up to the wrong spot. Blowing instead of sucking? since those seem like the likely parts you had to touch during your work... Double check those are all in the right locations.

 

[Motorhead]

Did not touch or re-route any motor or turbo components, that is what is so wierd ! Sounded very bad, exhaust note was not correct neither was the sound of 1 cylinder bypassing or passing pressure under cowling. Not sure if somehow it hydro locked when starting and or an exhaust gasket also blew during the short time I ran it!

Will have to buy a compression gauge and do that check once I tear all apart for inspection. I hope it is something simple rather than internal !

 

[mbarryracing]

Did you happen to stuff shop towels / rags in the throttle bodies when you had the intercooler off? or in the charge tube? Leave something in there, or something like a tool or bolt / nut, etc inadvertently got dropped in there?
Yank the intercooler back off and look down the throttle bodies to see if you have something that got left in behind and sucked into one of the intake valves... Check the charge tube, as well.

 

[Motorhead]

Yeah that thought crossed my mind many times but I had a towel across the entire intake and did check the throttle body butterflies prior to installing the intercooler! Should I tear the turbo apart to replace center seal at this point?

 

[mbarryracing]

The turbo will be fine, you didn't run it that long. But youre gonna have to clean the oil out of everything.

 

[Motorhead]

Was able to work on my sled every night after work this week except for Monday, and this is what I found! Pulled the plugs, cylinder #1 plug was wet all others were dry. No damage to plugs ( first sigh or relief). All cylinders had comparable compression, (second sigh of relief). Found alot of oil in tube that feeds the intercooler, it collects at the low spot in that pipe by the disc rotor. Ounces of oil poured out of that joint when I took it apart. Also found alot of residual oil in intercooler, and as I was taking the intercooler off for inspection and cleaning, I noticed that it had blown off at the motor(third sigh of releif). Many hours later, new plugs, all cleaned and reassembled it fired up and sounds and runs nice (last sigh of releif)!! So thanks to all for the advice, I really thought that the engine was damaged when it first started whereas the starter forced to turn it over and by then it was too late, exhaust was coming from the intake and it just sounded terrible. Guys on this site are very helpfull as was Justin Fuller !! Very happy with outcome Thanks again...