3200 Turbo Failure

[deano]

Good evening Guys,just thought it was time i reported and share with you my findings of my recent Turbo failure,The Tubo appears to have suffered from an over speed,,This i /we believe was caused by an imbalance in the wastegate actuator settings,creating an imbalance in the boost pressure and over working the other,although they share a common plenum both need to be in synch with each other or the pressure of the turbo that is breaking off on the wastegate later can stall the other,sometimes niticed by a chirping sound as the turbo is stalling,
As can be seen from the images this has resulted in the compressor wheel-turbine wheel shaft being sheered,with such a force the shaft has bent and also when the turbine wheel has come into contact with the housing resulting in the centre nut undoing and finding its way into the airbox,Be warned,

 

[CatmanV2]

Ouch!

C

 

[deano]

ouch,just about sums it up,though very lucky not to ingest any pieces,that would be a big ouch

 

[Almichie]

Did you have both Turbos overhauled? Have you refitted standard turbos back in?

 

[allandwf]

Agreed, lucky to keep "bits" out the engine. Should be a straightforward fix all going well.

 

[deano]

both turbo assemblies replaced,along with all the turbo services,after all both had done the same millage as far as i know,and both worked hard.

 

[deano]

and back together

 

[Almichie]

Did the engine have to come out for the change Deano? Looks very neat, clean and tidy all back together

 

[deano]

I took it out yes, made life easier, also had a weeping crank seal, so was just easier to remove.

 

[Almichie]

I took it out yes, made life easier, also had a weeping crank seal, so was just easier to remove.

Front or rear seal Deano? Was it easy to change?

 

[allandwf]

Job well done

 

[deano]

rear seal,yes was easy,

 

[alfatwo]

Did you refit the old clutch..

Dave

 

[Contigo]

So can anyone elaborate how to prevent this? Do we know the cause?

Also how many miles Deano?

You plenum chamber looks like it has been stove enameled! Why so clean?

 

[jluis]

So can anyone elaborate how to prevent this? Do we know the cause?

Also how many miles Deano?

You plenum chamber looks like it has been stove enameled! Why so clean?

Was going to ask the same.
How did you get that finish on the plenum and spark coil covers?

 

[deano]

All I can say chaps is make sure all your boost control an dump valve hoses are in top condition,and that the wastegates are set the same bank to bank,they are adjustable ,and are pre set fro the factory,but like everything they wear ,and come out of spec.the diaphrams inside can become weak,It is not an easy job to do due to lack of access as you well know,and is done by attaching a DTI clock to the wastegate arm and a measured pressure applied to the wastgate capsule,and record at what pressure the wastgate starts to lift off its seat,and pressure at various lift points in MM,
Though due to no actual set point available I set both turbo's the same.taking the data from a new turbo.
The car had done 100,000.

 

[Contigo]

High miles then really. What amazes me is your engine bay is cleaner than both my 3200's and they have done 1/3 and 1/2 your miles respectively???????

Have you had coil pack/cam covers painted and plenu refurbed or stove enamelled Deano?

 

[Contigo]

Something like this professional job.

 

[deano]

Yes plenum was chemically dipped along with coil packs and re sprayed,im a little anal like that I am afraid,Yes is relatively high millage when turbo failed,though I do not have any data to say when they start to go out of balance,Contigo,you will have to polish up the Maserati logo on the cam covers

 

[Contigo]

Nice job, and you were thinking of selling/breaking? Hmmmm

Well I need to get my mechanically 100% as I'm more anal about those things than an engine bay!