I would use air conditioner flush to clean the intercooler.:twocents:

I've never really felt ok with an oil-less turbo. So, you add grease every few thousand miles, but you never open it up and clean out the old grease - how does it not turn into a sticky gummy mess after 30k miles?

:iagree:

For the industrial bearings I've worked with, the new grease pushes the old grease out the sides of the bearing (or some type of vent). In the case of a turbo, I would assume most of the grease will ooze out on the exhaust side and be sent out the tailpipe.

Based on my experience with high-temp bearings, I would give the bearing a shot or two of grease* much more often than 3000 miles. Maybe once a week for a DD.

YMMV. All my experience is with industrial equipment and not turbos.

* Just how much would depend on type of bearing, size, etc.

Yea that's me. Fully built block with Comp bp kit. When everything was done, started the car, everything was good for about 10 min, then I noticed a slow drip of coolant from the exhaust. Started checking everything I could, made sure to verify it wasn't coming from the engine since I just built it. After removing the turbo and removing the housings, I found the turbo housing soaked with coolant. Turbo manifold was dry, indicating turbo seal coolant leak. Sent back to comp, they replaced the entire center section, and had it back within a few days. Comp was actually a pleasure to deal with, and they corrected the problem quickly, and correctly free of charge with free return shipping.

Since this failure, I have put about 1000 miles on the car with absolutely no problems. These turbos are fairly new, maybe its a quality control issue, maybe its a poor design, I am not sure. But I can tell you, they will warranty it for you, and everything is running perfectly since being replaced. I will be greasing mine every 2000 miles or so, personally think that is the longest that should be gone.

Call Comp directly and get it handled. The guy I dealt with was Joe.

Just to clarify for all the community here, Sasha has been great and I do not have any issues with him or his product....just the turbo from Comp.

I had the same coolant seal issue, was pushing out coolant smoke out exhaust. Sent to them and they fixed it and sent back. Have about 3k miles on her now running good.

That's interesting, same issue as me. Sounds like a quality control problem more than a design flaw.

Altogether much less concerning than the OP's issue which could result in metallic dust finding its way into the combustion chamber...

That being said, I've seen a few turbos go south like this in my time as a car enthusiast and none of the motors seemed any worse for wear.

Yea, metal particles are concerning. I would inspect inside the intake manifold, and all intake piping/intercooler for debris. clean everything thoroughly, change oil and filter, drive a couple hundred miles, then change oil and filter again. You should be fine.

In most bearing set-ups that I have dealt with. There is a hole that has a pipe plug in it that has to be removed when greasing the bearing. The hole is 180deg from the zerk fitting. This hole is where the old grease is suppose to come out of. If the old grease is hard. You have to use something to poke a hole in the hard grease to get it to flow out of the hole. An auto-greaser might work. We was trying these when I retired.

Ya the coolant leak isn't very damaging compared to the metal shavings going into your engine. But seriously it's like I'm expecting my turbo to fail when I put it in. There's been what 9 new VHR comp turbo kits and maybe 10 HR kits. Out of 19 comp turbos not one not two but THREE turbo failures. That's just insane.

I'm sorry I love BP and Sasha's customer service but I think we should have stuck with the precision turbo.

It's probably worse than that. We don't know whats going on with the other kits. As far as Comp kits go, 100% of the ones we've heard about have had issues. One wasn't the turbo itself, but then again, maybe it was. The filter melted and split. Too much heat? Imagine running w/o a filter and not knowing it.

People still have the option of going with the Precision turbos from Sasha. As far as the filters in my own experience relocation would be optimal but we know that is'nt an option. So you're left with heat mitigation or fabricating a shield. I'm on my third filter now; The first was completely my own ignorance as a result of removing the turbo and reinstalling it to many times and flattening the gasket. The second filter bubbled around the snout and eventually cracked open at the base. I sent pics to Buschur Racing and they said they don't know and had never seen it happen. I've gold wrapped the base of the third filter and we'll see the results when I snatch it off.

I was thinking about taking the intercooler to a semi repair shop, figured they would have some type of cleaning tank for the big intercoolers for the semi's.