It never rains but it pours - Diagnosis help guys

[Azman]

Morning all,

Having a bad one......

Story.....

On the way to the gym after work got to the road in Hinckley on the way to the windmill round about (milestone pub on teh way to the fields gym) Driving down form the roundabout at the top for wykin no probs at all, changed from second to 3rd all good, (not hard driving BTW) and then 4th hit about .5bar of boost and then bang, loud pop from teh engine and the whole car died. I tried to restart on the run but to no avail. Car ground to a halt. I pushed it round the roundabout into halfrauds car park and have just got home after a tow from the AA man. He was a nice man too (as per the old adverts) Young chap who took alot of interest in the engine but didn't really want to play with it.... Can't fault the guy aas he didn't want to possibly do more damage.....

Now then

On searching round the engine bay found that the turbo to intercooler hose had been blown off. This was secured with a magalor clamp (not the right name but something like that.. You know the big ones that have a thick stainless band and clamp properly... Well that is no where to be seen either.... Popped into halfrauds and bought a jubby clip and put that on with the AA man ( I am piddle wet through now from being on the floor)

Start the car thinking that could be just the problem, didn't want to start, eventually did and then died. Not risking starting it anymore so towed home.....

Now symptoms.....

(I did a fluid check on sat BTW and all was well)

Not wanting to start....
Now have a small build up of white residue on the filler cap....
Thick black smoke out of the exhaust when it did fire....
Noticed that there is a brown oily type residue coming from the injector seal on cylinder1 (front of car).......
Having enough pressure to blow that bleeding hose off in teh first place the thing was done up tighter than the proverbial nuns bits.....

Lookign round the bay there are no signs of oil seepage down the side of the block and the pressures were fine coming home from work this morning......

Come to think of it I had been thinking that the oil temp rises a bit to quickly after the car is started recently........

Well I now have a fubard car on the drive and only the money for the spray job left to work with which is a poltry £260

Advice or big diagnosis help please guys....

Head gasket or worse (well lots worse really)


Cheers Az

[Nj]

i'm afraid i've got fak all of any use to say to you except 'there there' and a pat on the head. That's a total ballache mate. Hope you get sorted out soon.

[Dubbedup]

Just a thought, but have you checked the timing belt?

Would it have snapped? jumped a few teeth?

Vag.com? Have you checked for any codes?

[Azman]

Now there is a thought. I haven't moved the timing in any way since the engine has come out and in but did check the belt over to see if it needed changing....Hmmm Have to go have a look for the timing marks lining up
When it stops raining that is....

[jameswkr]

Before you commit seppuku..the hose that blew off also has the side feed to the DV. Your symptoms suggest unmetered air getting into the system. I would remove the hose completely and inspect for damage ( I am surprised it could blow off one of those clamps but it might have split where the clamp sits ). It would seem unlikely (but not impossible) that the cam belt would go at the same time as a hose popping... I would also check the MAF connection and reset the ECU. Let us know how it goes..good luck!

[Acidburn]

You say that theres a small amount of white residue on the oil cap, could just be from where it was standing whilst you worked on it, did you check the water to see if it had any sort of oil film on it, and could also see if anything like that is on the dipstick.

Hope you get it sorted and will be interesting to hear what caused it, is it still waiting for a remap or did you get that done?

[Azman]

Still waiting for a mapp at the mo but it should not be to bad with the setup it has due to the last RR reslutls showing serious lean running so with the extra pressure behind the FPR (now being at 4bat instead of 3.5 (ala 3B) it should be bang on if not a little rich...

Right all the plugs are sooty black(rich running me thinks a tad) the timing marks line up on the outside of the engine and I haven't touched the cams at all sine I have had the engine so the timing should be bang on really. It was when the engine went in.....
Timing belt is still nice and tight with just a little bit of bounce when pressing the long runn form the water pump to the cam gear.

Found teh source of the brown seepage the helicoil that the injector sits in was loose so anything will blow back through that if it gets the chance. As it has.

Tightened up, left the plugs out to let the cylinders dry a touch as all the plugs came out very wet..... Poss flooded from blowing the turbo hose off???

Will put it all back together in about 30 mins and give it another try...
After resttign the ecu that is...
Az

[mcandmar]

Just thinking out loud here, the hose that blew off could have been the result of a backfire?

Oh and check the dizzy (if you have one) to make sure its still working and your getting sparks. I would explain all the fuel if the ignition timing is way off or not firing properly.

[Crawford_S2]

Dude it sounds like there is some weird stuff going on here, i would find a local mechanic thats knows his way around an S2 and keep your fingers crossed.

[Error404]

ok well i have had a timing belt slip on me before, and made a nasty piston valve interface. If that had happened you'd have felt a massive bang through the whole chassis, steering wheel, seat - everything. also it made a real nasty clanking sound trying to restart it so it ain't that.

Lots of black smoke when it went is probably just unburnt fuel?
I have had Mikalor clamps "blow" off before on ym 200sx, running a lot less boost than you are mate - i really don't rate them for clamping anything but the finest quality silicon, also unless you get the size bang on, i.e. its a struggle to get it on in the first palce i found they deform the pipes your are clamping and don't give a good seal.... maybe that was just my alloy hardpipes though

Anyway, sure something else hasn't blown off? Definately sounds like you have a gaping hole somewhere in the intake

like Acidburn said, i've had a bit of mayonaise build up on the filler cap when its been standing for a while - its probably just condensation

Have you done a boost leak test?

I can put some money your way for those bits too

[Azman]

Good news. I have been for a qick drive in it after putting it all back together and it purred like a kitten.....
Until 3 to forth gear change and pop off comes that hose again.
I heard the jubby clip hit the road and slammed the anchors on to rescue it so I could get going again

Took the hole lot off whilst nerly getting ,y legs run ova by a nova

The hose has ripped at the top where it links to the turbo so guessing that the clips have been on too tight and gradually worked through it leading to the busting of the pipe.....

So new pipes to be made up (prob going to get a solid pipe with mandrel bent ends and just use samco joining sections to sort that)

Other than that the car is running very well indeed. Going to replace the dizzy cap and rotor arm tomorow as a precaution and with regards to the timing. The spark marks are slap ang in the middle of the points. If the timing was out any the points move further off center showing the timing is out, so that all looks good too.......

Just got to get to the bottom of the little bit of white stuff on the bottom of the oil filler cap. Prob just condesation at the best as there is not much of it at all..... Will keep an eye on it and if more becomes visible then I will have to do a head gasket investigation....

Views on the above please folks....

p.s. cheers for the pointers. the one that is ticking in my brain is the missfire opinion? any other thoughts on this guys???

Az

[Azman]

@ Error and Acid.

The dipstick is clear and the oil level hasn't changed.
The water is fine just a little rust mucky (could do with another flsh through me thinks)

One thought would be the FPR is too high as I am running a 4bar AAN one....
Any thoughts on dropping it to a 3.8 and which internals will fit in the AAN housing???
Az

[Acidburn]

Whats the weather been like up there, dry or damp as if its damp it could have got in somehow and caused it?

[Azman]

Ar damp, wet, well like this mornign on the way to the gym wearin a sleveless top, shorts and my boxing shoes and the car conks out......

Soaked to the bone after pushing the thing around the roundabout...... Will have to take a picture of the bruises and blood marks on my shoulder for proserity... This car has scared me (both physically and mentally!!!) the most out of every car I have had..... Jees what a roller coaster ride!!!

[Acidburn]

But its worth it in the end... apparantly