Seized turbo-need tips/advice

[TurboSteve]

Hi everyone,

I have a 2003 WRX with 176K on it. It also has an STI catback and '07 WRX wheels, but otherwise it is stock. It would seem that the turbocharger has locked up. The car is down on power considerably, seems to be running a bit weird, and according to the gauge, it is no longer making boost. I've verified that the waste gate arm is still attached, so i'm going to pull the turbocharger to verify that it is indeed seized.

The car spent its first few years in New Jersey, so every bolt under the hood is pretty rusty. I've already snapped off a couple of the heat shield bolts despite soaking them with PB Blaster-i had a feeling this would be the case.

While i'm in there, i'm going to take care of some maintenance items like replacing the fuel filter, changing the spark plugs, changing the cam cover gaskets, replacing the passenger-side front CV axle, and of course, replacing the turbocharger if needed. I'm considering replacing the factory up and downpipes with some aftermarket pieces if i have enough money, otherwise i'm going to replace the exhaust gaskets and try and find some new factory heat shields.

Despite living in Florida, we have noticed the gas seepage/odor during cold snaps that i believe are coming from under the intake, or so i've read. I think i did see puddle of fuel at one point, so i'm considering fixing that, too.

With all of that said, i was wondering if anyone had any tips, things to look for/expect, other parts that will probably need to be replaced, etc.

Thank you,

Steve

[jcssti6265]

Hi everyone,

I have a 2003 WRX with 176K on it. It also has an STI catback and '07 WRX wheels, but otherwise it is stock. It would seem that the turbocharger has locked up. The car is down on power considerably, seems to be running a bit weird, and according to the gauge, it is no longer making boost. I've verified that the waste gate arm is still attached, so i'm going to pull the turbocharger to verify that it is indeed seized.

The car spent its first few years in New Jersey, so every bolt under the hood is pretty rusty. I've already snapped off a couple of the heat shield bolts despite soaking them with PB Blaster-i had a feeling this would be the case.

While i'm in there, i'm going to take care of some maintenance items like replacing the fuel filter, changing the spark plugs, changing the cam cover gaskets, replacing the passenger-side front CV axle, and of course, replacing the turbocharger if needed. I'm considering replacing the factory up and downpipes with some aftermarket pieces if i have enough money, otherwise i'm going to replace the exhaust gaskets and try and find some new factory heat shields.

Despite living in Florida, we have noticed the gas seepage/odor during cold snaps that i believe are coming from under the intake, or so i've read. I think i did see puddle of fuel at one point, so i'm considering fixing that, too.

With all of that said, i was wondering if anyone had any tips, things to look for/expect, other parts that will probably need to be replaced, etc.

Thank you,

Steve

what ive found on these northern cars is usually the uppipe breaks causing a lack of turbine spin, not the turbo seized. does the car have a big exhaust leak?

[TPNORTH]

^ ive herd its very common on the older wrx models 02-05 when they still used cats in the up pipe.

[TurboSteve]

The car doesn't seem to be abnormally loud, and it doesn't tick or pop like most exhaust leaks i've heard. I'm going to get the car on jack stands tonight and try to look at the up pipe just in case.

i would think even if it was cracked, that it would make some sort of boost, but i could be wrong.

[EclipseGT01]

It should create some boost even if their is a crack due to air speed velocity through the pipe. You might not crate 13psi, but it would give you a few PSI on the gauge. Other thing is to take the downpipe off and spin the turbine on the back side of the turbo. If it still spins, then its not the turbo. The fuel issue is a bad O-ring on one of your injectors. Easy fix. I've done a few on my car. Also, another good part to replace after a while is the PCV valve. It's a $10 part at the dealership. Might as well replace it if you are doing some routine work.

[TurboSteve]

Well, i didn't get a chance to look under the car tonight as i got home late, but i'm going to try and take a look at the up pipe and if that's good, then i'll proceed with pulling the downpipe and spinning the wheel.

I thought the gas seepage was from a fuel line that shrunk when it was cold out side. Do you need to get the injector O-rings from the dealer?

Thanks,

Steve

[EclipseGT01]

not really. You can get a set of O-rings from auto zone or advanced. I can't remember the size, but I'm pretty sure that's your issue. They are rubber, so they will eventually wear out.

[TurboSteve]

So this is how far i got two nights ago when i started.

[TurboSteve]

I was removing the under tray just a little while ago, looked over at the airbox on the ground and saw something in the inlet port. I opened the box up to find this:

[TurboSteve]

I'm doubtful that it only took two days for a mouse to eat that much filter AND several of the plastic ribs from the box. After finding this, though, i think i really want to take a look at the turbo inlet before tear the exhaust apart. Can the inlet elbow be removed with the intake manifold on? I can't seem to get it to move.

Thanks,
Steve

[Golderon24s]

what ive found on these northern cars is usually the uppipe breaks causing a lack of turbine spin, not the turbo seized. does the car have a big exhaust leak?

My car was from up north also and I had the almost the same issues. The guys @ TampaBay Tuned hooked it up and saved me a boat load of money and aggravation.

[TPNORTH]

you can pull the inlet without taking the intake mani off but its a HUGE BITCH! If i were you id pull the turbo and up pipe youll get both your answers there and you can see through the inlet without having to pull it! Gl man if you need help feel free to hmu

[TurboSteve]

I finally had time tonight to work a bit on the car, and I decided to put a vacuum on the end of the intake tube. How much air filter material does it take to jam the turbo?




I'm still going to pull the intake anyway as i want to fix the fuel leak recall issue and check out the compressor wheel fins. It took a few "pulls" from the vacuum before the turbo got up to full speed, but it seems pretty clear.

[EclipseGT01]

I'd say if any of that got in your turbo, it may be done. If any got past the turbo, then your intercooler may be clogged as well.

[TurboSteve]

The intercooler was clean when i pulled it, as was the turbo discharge side. I cracked down tonight and got the intake manifold off finally. The impeller blades are just fine. I'll post a picture tomorrow once i pull it off my camera.

i can't really tell exactly where the fuel was leaking, so i'll probably replace all of the injector O-rings as well as the recall repair parts.

Steve