Van turbo overhall

[merckx]

I've got a problem with my van which I use for work.:(

It's a Peugeot Boxer 2.8 HDI, 65,000 miles and it does get a fair bit of abuse.


I'm amazed at how small the turbine wheels are compared to the ones that I've seen on here.:blink:



I've been burning oil just recently which is getting worse, I did a visual inspection on the turbo and I saw an oil stain on the housing. There was also more axial play on the shaft than I expected.


So I decided to take it apart and replace the journal bearing and seals etc, but I've encountered a couple of problems.


1. The ceramic exhaust turbine has a small crater as you can see in the pic.


http://i4.photobucket.com/albums/y122/rexmerckx/vanturbo1.jpg



2. The thrust washer and seal plate which you can see in the other pic have annular wear rings, I'm assuming that the small thrust washer wasn't like this when new.



http://i4.photobucket.com/albums/y122/rexmerckx/vanturbo2.jpg




The refurbishment kit doesn't include the thrust washer but you do get the brass seal plate which is the one that has most of the wear.

Should I assemble it with the worn thrust washer and an exhaust turbine with a small crater, I'm thinking that it wouldn't be a wise thing to do?


Any advice please. :)

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[Chris Wilson]

It's lost a piece of ceramic, this may be the real reason it's burning oil. I'd get a pro turbo place to look at it, or maybe find another used core to rebuild? To be honest i have never had any long term success with home grown rebuilds, probably because they can't be re balanced. Having said that I *KNOW* some commercial re builders don't bother balancing, but it still is wrong.

[merckx]

Thanks for the reply Chris.

I decided to get a new one which will come tomorrow, £480 which isn't that much more than the cost of getting it rebuilt which was going to take three or four days plus I haven't really got the time to wait.

What a pain in the arse it was to remove though, the van has a transverse engine , you can get to the turbo from underneath but only at arms length which is the main problem . I could only use a spanner as there was no room for a socket, impossible to get any leverage on the spanner with my arm outstretched.

All the nuts were far too tight, I used a spanner and attached some strong cord up into the engine bay and got my brother to pull it with finally loosened the nuts. :)

[merckx]

Fixed, no more smoke. :)