Metal in the Intercooler (with pictures)

Engine toast?

  • Yes :(

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  • Maybe

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    1

danmin

Veteran Member
Joined
Oct 6, 2023
Location
DFW
TDI
2014 Passat 2.0 TDI @ 180k
Turbo blew and I’m replacing that plus my DMF, oil pump hex shaft, mounts, timing service and the upgraded oil cooler all in one go.

I’ve got my car in pieces right now about to pull the engine and I eventually pulled the elbow connecting the turbo to the intercooler at the front. Found metal pieces and a pool of oil in the bottom of the intercooler. Also part of a big O-Ring.

I turned the car off as soon as I heard a “pop” come from the engine bay. Engine ran for maybe 2 seconds after the fact before I turned it off. I’m worried metal got into the engine from the turbo going.

What are the odds of metal bits harming the engine? What would be the result if so. Is a tear-down warranted? I was hoping I wouldn’t have to crack open the engine… Also what could possibly be the rubber o-ring I found?

With so many CKRA owners having blown turbos- I doubt each victim had to replace an engine or tear apart their intakes to clean them of metal. Just hoping for the best and preparing for the worst I suppose. I don’t want to get the car in running condition after all this just to shred the new turbo or rio the pistons and valves up.







 

Ackilys

Vendor , w/Business number
Joined
Jul 1, 2012
Location
Ontario
TDI
‘09 Jetta dsg, ‘11 jetta 6spd, ‘13 passat dsg
I’m told compression test it. Should be 550 psi if I’m remember correctly?
 

Tom in PT

Veteran Member
Joined
Jun 7, 2017
Location
Twilight Zone, WA State
TDI
2005 Passat sedan - SOLD; 2013 Passat DSG; both purchased new
I think its unlikely the metal got into the engine if you shut it off so quickly. But I would completely clean out that intercooler - who knows whats up there, (I know, its obvious). That O ring might be from a oil seal in the turbo that blew up.
 

2004LB7

Veteran Member
Joined
Jun 2, 2013
Location
California
TDI
2006 Jetta
Intercoolers are pretty good at filtering out particles. How does the outlet side of the intercooler and intake manifold look? Any signs of metal?
 

danmin

Veteran Member
Joined
Oct 6, 2023
Location
DFW
TDI
2014 Passat 2.0 TDI @ 180k
Just put the intercooler back on after doing a few other things with the motor removed. Cleaned it out pretty good and ran a hose through it (backwards) for 2 hours to make sure there wasn’t anything in it. I didn’t see anything come out when cleaning it. Just a lot of oil and oily sludge. I didn’t go through the sludge but I imagine that captured some particles.

I took a borescope and looked in the manifold but it was way too dirty with black buildup to see anything. I checked the exhaust valves since the turbo is off and I saw some “glitter” but not a lot and the exhaust valve edges weren’t visibly damaged. I’m gonna run it when the new turbo comes in and hope for the best
 

740GLE

Top Post Dawg
Joined
Aug 19, 2009
Location
NH
TDI
2017 Alltrack SE; Totaled 2015 Passat SEL, BB 2010 Sedan Man; 2012 Passat SE w/ Nav,
whats that in the DMF DSG input shaft? looks almost like needle roller bearings all loosey goosey .
 

p.e.fletcher

Veteran Member
Joined
May 21, 2019
Location
Tallahassee, FL
TDI
2013 Passat TDI SE/2011 Golf TDI
dang hopefully no internal damage to the intercooler itself because it’s water to air can leak coolant and blast it into your manifold. did you happen to pressure test it?
 

danmin

Veteran Member
Joined
Oct 6, 2023
Location
DFW
TDI
2014 Passat 2.0 TDI @ 180k
dang hopefully no internal damage to the intercooler itself because it’s water to air can leak coolant and blast it into your manifold. did you happen to pressure test it?
I didn’t exactly do a pressure test but I cleaned it out both through the coolant passages and the airway and didn’t see any water/bubbles collecting anywhere it shouldn’t have
 
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