Technical GP T-Jet Oil Consumption

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Technical GP T-Jet Oil Consumption

The separator is the big black plastic box-like thing next to the coils, it's attached with a few 10mm bolts ( maybe 2 bolts and one nut) and it has hoses atached ( one going to the intake manifold and the other ( bigger one) goes to the intake pipe before the turbo.
remove the bots and hoses then lift it up.

Looking for the breather, I cant seem to find it.

I don't suppose it would be too much to ask to post an image of it? You mention a box, but all I can see online is people talking about the pipe (https://www.fiatforum.com/grande-punto-guides/262269-breather-hose-replacement-1-2-1-4-8v.html)
 
Ah, I think it worked out what you meant now.

In the process of taking off the cover, I discovered that the back part was COVERED in gunk and grease (The red circles in the images). So cleaned that all off.

After reading what you had described a few times, it hit me. For the oil breather, are you talking about the box highlighted in blue? For the longest time I thought you meant the engine cover. If that is the box that you meant, how do you go about taking off that cap? I'm thinking about trying to pressure it off with a flathead screwdriver over those tabs that hold it on.
 

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Nephews seat and corsa both used oil, both breathers were blocked . .
Your basically pressuring the oil scraper rings forcing the oil up instead of letting it return to the sump.
 
Yes, the thing circled in blue is the oil separator.
On mine, all the hose clamps were easily taken off with a small flat head screwdriver.
Then remove the bolts and gently lift it up ( it has a nozzle inside the valve cover with a rubber seal on it try not to damage it)

After you've taken it off the engine work on taking the cap off ( much easier not having to bend over the engine bay); push it over the locking tabs using one or two flat head screwdrivers.

This is how you test to see if it's not working properly:
1-blow air (with your mouth...wipe first) on the nozzle that goes in to the valve cover; if it's easy to blow air through it then it's stuck open and a lot of oil will be constantly sucked into the engine. If it is to hard to blow air through or impossible then it might be stuck closed and oil will be pushed back into the cylinder past the oil rings, and the oil will be burned like that. In normal operation some pressure will accumulate until it can push a spring loaded membrane (you will see the membrane and spring when you take off the cover) and only then go into the engine.
2- Try to suck on the nozzle that goes to the intake manifold. You should not be able to suck much air because there is a flap/valve that should close when you do that ( if you can suck air in through there then that is a definite vacuum leak). Also try to blow air through that nozzle. you should not be ale to do that because another flap should block air going in that direction ( if you can blow air that way then you have a boost leak => loss in performance)
3- Blow through the nozzle that goes to the pipe before the turbo.
You should not be able to do so ( another valve). Suck through it, you should not be able to do so.

If you can suck/ blow air when i said you shouldn't that only means that the valves/flaps are stuck opened. You can clean them loose ( i did with oven cleaner and a lot of hot water)
To clean it take off the cap and thoroughly clean the membrane and spring as well as the holes/passages you will see.
Psut generous amounts of cleaner in all the hoes.. let it soak..scrub(when possible).. rinse.. repeat.

With the cap and membrane+spring taken off you should be able to :
-blow and suck air through nozzle to the valve cover
-suck air through the nozzle to the intake manifold. Not be able to blow.
-suck air through the nozzle to the pipe before the turbo. Not be able to blow.
 
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Thank you for all the advice, will work on it again tomorrow first thing :)

Will update you on the results.

Thanks,
Will
 
Yes, the thing circled in blue is the oil separator.
On mine, all the hose clamps were easily taken off with a small flat head screwdriver.
Then remove the bolts and gently lift it up ( it has a nozzle inside the valve cover with a rubber seal on it try not to damage it)

After you've taken it off the engine work on taking the cap off ( much easier not having to bend over the engine bay); push it over the locking tabs using one or two flat head screwdrivers.

This is how you test to see if it's not working properly:
1-blow air (with your mouth...wipe first) on the nozzle that goes in to the valve cover; if it's easy to blow air through it then it's stuck open and a lot of oil will be constantly sucked into the engine. If it is to hard to blow air through or impossible then it might be stuck closed and oil will be pushed back into the cylinder past the oil rings, and the oil will be burned like that. In normal operation some pressure will accumulate until it can push a spring loaded membrane (you will see the membrane and spring when you take off the cover) and only then go into the engine.
2- Try to suck on the nozzle that goes to the intake manifold. You should not be able to suck much air because there is a flap/valve that should close when you do that ( if you can suck air in through there then that is a definite vacuum leak). Also try to blow air through that nozzle. you should not be ale to do that because another flap should block air going in that direction ( if you can blow air that way then you have a boost leak => loss in performance)
3- Blow through the nozzle that goes to the pipe before the turbo.
You should not be able to do so ( another valve). Suck through it, you should not be able to do so.

If you can suck/ blow air when i said you shouldn't that only means that the valves/flaps are stuck opened. You can clean them loose ( i did with oven cleaner and a lot of hot water)
To clean it take off the cap and thoroughly clean the membrane and spring as well as the holes/passages you will see.
Psut generous amounts of cleaner in all the hoes.. let it soak..scrub(when possible).. rinse.. repeat.

With the cap and membrane+spring taken off you should be able to :
-blow and suck air through nozzle to the valve cover
-suck air through the nozzle to the intake manifold. Not be able to blow.
-suck air through the nozzle to the pipe before the turbo. Not be able to blow.

My god, that cap was a bastard to get off.

After taking it off the engine I took the cap off and tried the tests, it failed on most. I've given it a good clean with hot water and engine de-greaser, with loads of chunks/specs of black sludge coming out. It got to a point where not much more was coming out and I stopped.

With the cap off, and clean,
- I could blow and suck through the valve cover nozzle.
- Suck through the intake nozzle, not blow,
- And suck through the turbo pipe, not blow. So passing what you mentioned at the bottom.

With the cap back on, I tried the original blow/suck tests again.
- It is still very easy to blow air through the valve cover nozzle, coming out of both the turbo and intake pipe nozzles.
- I was able to suck large amounts through the intake manifold nozzle, but not blow. I couldn't suck much at all with the valve cover nozzle blocked with my finger, and none at all with both the valve and turbo blocked.
- I am also able to suck through the turbo pipe, but not blow. Again, I couldn't suck much at all with the valve cover nozzle blocked with my finger, and none at all with both the valve and turbo blocked.

When shaking the box around, I can hear a rattle from inside. Is this normal?

I'm going to put it back in now as there is no more cleaning that can be done. Could this mean that the part is broken?
 
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Ok seems fairly good.
What is the condition of the diaphragm?
did you clean it, as well as it's mating surface,
did you make sure to put the spring back together exactly where it came from ( i.e between the cap and the diaphragm ) and in the same direction?


TBH, i don't think it really hurts if the diaphragm doesn't seat properly and seal tat passage. oil gasses will just not build up as much pressure.

As to the noise:
I think that's just some more grime/ crap or you just heard one of the flaps closing.
From your tests, i say that the only two moving parts are still working properly.

Only problem would be if it's a piece of crap it might get logged inside one of the flaps/valves and this way cause mote trouble in the future, or worse .. get sucked into the turbo, or the engine.
 
Ok seems fairly good.
What is the condition of the diaphragm?
did you clean it, as well as it's mating surface,
did you make sure to put the spring back together exactly where it came from ( i.e between the cap and the diaphragm ) and in the same direction?


TBH, i don't think it really hurts if the diaphragm doesn't seat properly and seal tat passage. oil gasses will just not build up as much pressure.

As to the noise:
I think that's just some more grime/ crap or you just heard one of the flaps closing.
From your tests, i say that the only two moving parts are still working properly.

Only problem would be if it's a piece of crap it might get logged inside one of the flaps/valves and this way cause mote trouble in the future, or worse .. get sucked into the turbo, or the engine.
Cleaned the spring and rubber part, rubber part had a small tear on the inside its edge, but didn't look large enough to be serious.

You say the spring setup should be between the cap and rubber thing? I thought that should be it's setup, but when it came out it went (from top down) cap, rubber/plastic thing, spring, oil seperator box. Are you saying that setup is wrong? Because, how I currently have it, seems to me like the seperator is always open.

Again, thanks for the advice and taking the time to reply,
Will
 
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Alright, had another look at it today.

Attached is the current set-up I have. I have the spring in the separator and the membrane in the cap with the hard plastic facing the spring, is this how it should be?
 

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Ok i have to admit it.. seeing this picture has gotten me confused,
That might be the correct way round.. but i can't figure out what would be the point of the diaphragm in this case ( maybe it' there so under big vacuum the gases don't go to the intake, maybe that would stall the engine???).
I'll go take a look at mine and post back.
 
Ok i have to admit it.. seeing this picture has gotten me confused,
That might be the correct way round.. but i can't figure out what would be the point of the diaphragm in this case ( maybe it' there so under big vacuum the gases don't go to the intake, maybe that would stall the engine???).
I'll go take a look at mine and post back.

Thank you, to me how it currently is, makes no sense at all, the spring is pushing the diaphragm up into the cap, leaving all those vents open all the time. But that's how it was when I opened it up.

I tried it with the spring in the cap, and the diaphragm in the base, plastic side up, and it produced an ungodly amount of squealing noise, coming from the oil separator.

I then tried it with the spring in the cap again, diaphragm in the base, but this time with the plastic facing down. It wasn't squealing, but when I tried revving the engine, a large plume of smoke came out. Not sure if this was from the set up I just tried, but I put it back to how it was originally (See previous image) and after 5 mins the smoke had stopped coming out of the exhaust, back to normal.
 
I checked, and it's the same as in that picture of yours.
when there is a big amount of manifold vacuum ( like starting, engine braking and maybe idle.. basically sensitive times) the diaphragm closes and no gases are drawn into the intake.
 
Try removing the inlet hose from your throttle body and see if there is any oil sitting in there. I recently had to change my turbo after doing just that. I noticed a lot of blue/white smoke on start up. was a small pool of oil sat in the bottom of the throttle body. With the inlet pipe still disconnected I turned the engine over and let the turbo spool up, it spat oil everywhere. Turns out my turbo had a faulty seal on the inlet side. New turbo from Fast Turbo UK, new egr valve and after cleaning out all the hoses, intercooler etc runs like a dream! Mines a 1.9 multijet but I assume it can all be diagnosed on the same principal. Hope it helps (y)
 
I'll give that a try, but I don't experience any smoke (Other than when I was playing around with the Oil Separator)

Not any oil used in the past 2 days, been checking regularly. Will update again at thee w/end. Hopefully cleaning it out fixed the issue.
 
take photos to record oil level and mileage (maybe even dates).
Mine was using a bit of oil (about 1 liter per 15k km) since i cleaned the oil separator it has gone down ( level practically the same 7k km after oil change) - that's why i recommended cleaning it!
 
take photos to record oil level and mileage (maybe even dates).
Mine was using a bit of oil (about 1 liter per 15k km) since i cleaned the oil separator it has gone down ( level practically the same 7k km after oil change) - that's why i recommended cleaning it!

Yeah, I have been keeping a visual library of the oil level. Thanks for the advice.

Again, bit annoying that I can't see instantly if its resolved.
 
After a weeks usage the oils dropped down to about 3/4 on the dipstick. Not as much as before, but still more than I'd like. Will actually have time to do the oil change tomorrow.

Can anyone recommend how I take out the current oil filter? Its in a really awkward position underneath the air intake/turbo. I'm thinking of taking the intake off.
 
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