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Project: AWD TURBO Family Hauler (04 Forester 2.5XT)
So Turbo was looked over and is ok, which means I have some other issue.

Quote:Our tech inspected your turbo yesterday and found the following:

Journal bearing 1: OK
Journal bearing 2: OK
Thrust bearing: OK
Turbine seal: OK
Compressor seal: OK
Shaft runout: <.0005
Turbine wheel: OK
Compressor wheel: minor tip damage -1
Bearing housing: OK
Seal bore: OK

Tech note:

Large amount of oil and coking under the heat shield. Some oil in compressor housing. Turbo otherwise operable without defect. No thrust bearing wear. Excess oil passing possibly due to incorrect oil feed restrictor, or engine defect.

From the tech's notes looks like you have a lot of oil passing either past the turbine seal or from the engine into the exhaust. The rotating assembly is in decent shape and no defects that would show failure. The question we would have for you is what kind of oil feed banjo are you using? Also how is the compression on the motor and is there any oil in the downpipe?

No evidence of oil starvation in fact it's the opposite. Looks like the turbo is passing oil but only slight wear that would indicate a problem with the turbo itself
...........

Oil leaking from a turbo when uninstalled and sitting is actually perfectly normal. The turbine and compressor seals are dynamic meaning they work with flingers while the shaft is rotating to seal and keep oil from passing. When stationary oil can work its way through the gaps.

The other possibility is blockage in the oil drain which would keep the bearing housing flodded and would eventually leak.

Also crankcase pressure could keep oil in the bearing housing causing your issues.

Would definitely have a compression check done. Not a leak down but individual test on each cylinder. As there may be an engine defect that is contributing to the problem. Would strongly consider that since the problem has occurred on two different turbos.

So with that, Oil drain is clear.

PCV seemed to be sticking and gunked with oil which would keep it from functioning as intended. Also had a cracked line that would keep it from functioning properly, so I ordered another one of those.

Need to do a compression check, but the fact that it had the symptoms with the TDO4, went away for 3 months while running the VF39, and is now back, makes me think it is a crankcase pressure issue forcing oil past the seals.

I am pretty close to just putting it back as close to stock as I can, taking it to Carmax, and walking away. This car has become a giant pile of bullshit, and I will likely never own another Subaru.

Options for replacements....I like the Mk6 TDI Sportwagens, but HPFP failure = $8k repair, so fuck that. Looking hard at TSX wagons, because it is an Accord wagon with shiny Acura parts, but I have not driven one yet.


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