Turbo Rebuild -diy

[simplegreen]

How to rebuild a turbo - Turbo Rebuild DIY

NOTE: that if you are going to do this yourself, you should scribe a line on the compressor wheel and shaft before removing it, and bolt it back on with the lines lined up to get it as close to balanced as possible. It is best to have a turbo shop do the rebuild, so they can balance the turbo afterwards (A turbo shop will also have ways to clean the parts properly, like using a beadblaster), but if you are on an extreme budget, you can try this and see if it works. I highly suggest you still spend the money to send it off to a turbo shop for balancing when you are done. I hold no responsibility if your turbo is out of balance and wears prematurely or grenades.

Tools needed:

* Open-end wrenches
o 12, 13mm
* 1/4" ratchet
o 10, 12mm sockets
o 6" extension
* Circlip pliers ($15-20, Sears)
* Needlenose pliers
* Flatblade screwdriver
* Razorblade scraper
* Hammer
* LOTS of cleaner
* Turbo rebuild kit

Sorry for the huge space to follow:


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• The turbo in one piece. NOTE that if you aren't going to do any porting of the
  turbo, you can leave the turbine housing on the car. See the fourth pic for info.</p>

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• Removing the wastegate actuator (12mm).</p>

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• Wastegate actuator off.</p>

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• Removing the turbine housing band clamp (10mm). If you aren't going to port the turbine
  housing, you can leave the turbine housing on the car, remove the MAF hose, heatshields, oil and coolant
  lines, and the wastegate actuator arm clip from the turbine housing, then remove this band clamp, and
  pull the centersection and compressor housing out of the car. This will save you a lot of time over
  having to remove the downpipe/O2 housing, and maybe exhaust manifold from the car to remove the turbo.</p>

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• Pulling the turbine housing from the centersection. You may need to hold the compressor side
  and tap the turbine housing with a hammer to knock it loose. If so, hold the turbo barely above a pillow
  or something to catch it, hold the turbo with the turbine housing straight down, and strike at it parallel
  to the turbo centerline, so when it comes off, it comes straight off, and does not hit the turbine blade.</p>

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• Here you see two things - the small circle is the locating pin for the turbine housing, do
  NOT break this off or lose it, it helps align the turbo when putting it back together. If you break/lose it,
  it's not the end of the world, you just have to scribe marks on the outside edge of the mating surfaces so
  you can align it. The large circle is the end of the huge circlip holding the compressor housing to the
  centersection. You can use a fine-tipped needlenose to remove them, but a circlip pliers makes the job
  much easier, and is safer. You also need circlip pliers for other rebuild projects on
  DSMs, so go buy them.</p>

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• Circlip pliers in the ends of the circlip. I got the "deluxe" circlip pliers from Sears,
  then can be converted from inside to outside pliers instantly, and have several tips. I install the
  tips backwards in the pliers for this large circlip, because all the tips taper down to small ends
  which would break off when trying to move a circlip this large.</p>

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• This is after the clip is loose, but while you have the pliers contracting the circlip,
  stick a screwdriver under the circlip, and pry it up and out of its' groove, then work it off of
  the turbo. BE VERY CAREFUL, this clip is large and has a lot of force, it is hard
  to remove, and if you slip, it can hurt.</p>

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• Circlip gone. The circled area is the locating pin.</p>

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• Here's the centersection out of the compressor housing, a better view of the locating pin.</p>

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• Centersection removed from the compressor housing.</p>

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• <font color="#ff0000">If you are not sending your turbo for a full rebuild, MAKE SURE to scribe
  a line across the compressor wheel, nut, and the end of the shaft at this time. If you do not bolt it back
  together with ALL of the lines lined up, your turbo may end up being out of balance, and it can quickly
  destroy itself.</font></p>
  
  
  
  Put an open-end wrench on the "nut" on the end of the turbine wheel (can't remember if
  it is 12 or 13mm, but I have seen 12, 13, and 14mm), put a ratchet on the nut on the compressor end of
  the shaft (10,12mm?), and remove the nut. Be VERY careful of the wheels, the blades can really tear
  your hands up. It is safest to wrap them in towels, because if the nut breaks free and your hands hit
  either wheel, you could be seeing a lot of blood.</p>
  
  
  <font color="#ff0000">Texas Rebuild suggests to do the following - place the turbine blade "nut"
  in a vice, and either use a T-handle socket to remove the compressor blade nut, or when using the ratchet,
  make sure to hold the socket so that the ratchet is only twisting the nut, not placing any side load on
  the center shaft. Evidently it is easy to bend the center shaft if you place too much of a side load on
  it when removing the nut. When I removed the one in the picture, I was very careful to grab the ratchet
  at the rotating end and put all the twisting force directly through the socket, without putting any side
  load on the shaft.</font></p>

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• The compressor wheel off of the centersection. I didn't scribe the wheel and shaft because I
  had combined parts from several turbos, and sent the turbo off to be balanced after the rebuild.</p>

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• Put the nut back on the shaft, spin it on flush with the end of the shaft, and tap it
  lightly with a hammer to knock the turbine wheel/shaft assembly out of the centersection.</p>

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• Here's the shaft out of the centersection. That sheetmetal guard is NOT supposed to look like that...</p>

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• Left side, bad, right side, good.</p>

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• The centersections of two 14Bs, after the sheetmetal guard is removed. Left side, bad,
  right side, good. The left side shows severe coking. The shaft had totally
  locked up, but after cleaning all the coking off, it spun well again.</p>

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• Good centersection - still a little coking, but minimal, and easily cleaned up.</p>

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• BAD centersection - major coking, not easily cleaned up.</p>

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• This is after chipping off a chunk of coking, see how thick it got?</p>

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• This is after about 5 minutes of chipping the coking away by tapping it with a flatblade
  screwdriver, sometimes tapping very hard. It still needed further cleanup, soaking it for several hours
  in solvent should have done it, but I had Forced Performance beadblast it while they were doing other work to it.</p>

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• Left side, bad, right side, good. The left turbine wheel got torn up
  when something went through the turbo. Note the valley in the shaft that is pretty grainy on the left
  side - this is after cleaning it with a screwdriver. The right side shaft was almost as bad, I used a
  screwdriver and followed up carefully and lightly with a razor scraper, it is almost totally clean.
  Note the left shaft still has the bushing on it, I have removed the one on the right shaft.
  It just slides on.</p>

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• Here's a compressor side view of the centersection with the turbine shaft removed. The
  circlip holds a center cap in place.</p>

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• The circlip removed. Note the circled area on the end cap - there is a raised lip here.</p>

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• Place 2 flatblade screwdrivers 180 degrees apart under this lip, and carefully pry the end
  cap up and out of the centersection. You might need to move the screwdrivers around the lip and gradually
  pry it out, depending on how tight it is in there.</p>

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• The brass thrust bearing sitting on the centersection, oriented as it is in the centersection.
  Note the steel bushing in the center of the thrust bearing. Note the hole in the thrust bearing that fits
  over the rollpin in the centersection.</p>

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• The center cap and thrust bearing turned over. Note the oil feed journal in the thrust bearing,
  fed by the circled hole in the centersection.</p>

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• The steel bushing out of the thrust bearing. Note that the thrust bearing and its' steel
  bushing are upsidedown in this picture.</p>

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• The compressor side turbine shaft bushing removed from the centersection.</p>

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• Circled is a tiny circlip inside the center section. There is one on each side, they keep
  the center bushings from slipping into the center. I removed them using two pins to contract them,
  then pushed them out of their groove, then pulled them out with needlenose.</p>

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• Remove the compressor housing O-ring. Mine broke in several places while removing it,
  as it was dried out.</p>

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• Remove the end cap O-ring. Here the O-ring is part way out. Then clean the entire centersection
  thoroughly. Brake parts cleaner works well.</p>

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• The center cap with the springloaded plate on it. This pushes the thrust bearing against the
  turbine shaft, to keep it from moving end-to-end.</p>

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• Here's a 16G rebuild kit. Note that it is different than a 14B rebuild kit.
  The center cap has a different profile to match the back side of the 16G wheel.</p>

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• The 14B compressor wheel is on the left, the 16G on the right. Note that the back of the
  14B wheel is flat, while the 16G is tapered. If you were to put a 16G wheel on a 14B center plate,
  the wheel would be sitting too high on the centersection.</p>

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• The 14B center plate is on the left, the 16G on the right. Note the taper on the 16G plate.</p>

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• The old 14B spring plate and bushing on the left, 16G on the right. The top pic shows the
  spring plate, bushing, and sealing ring. The second pic shows the bushing in place, with the sealing
  ring above it. Carefully slip the sealing ring over the top of the bushing. It will be a loose fit.
  The bottom pic shows the spring plate assembly ready to go into the center cap.</p>

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• Front and rear views of the 14B and 16G center cap assemblies. When you press the spring plate
  assembly into the center cap, do it carefully, you want to slowly compress the sealing ring down until it
  tightly fits into the hole in the center cap. Make note of the gap in the sealing ring, and press the
  spring plate assembly into the center cap starting opposite the gap in the sealing ring, so that
  it can easily contract as you press it into place.</p>

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• Here is the old turbine shaft and wheel, with the old sealing ring in place.</p>

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• Slide two straightpins under the old sealing ring, and work it out of its' groove.</p>

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• Here the sealing ring is out of its' groove. Look at the groove carefully, and you will
  see that the groove is filled with coked material. I used a straightpin to clean the groove out.</p>

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• Here the groove is cleaned out. Even with the out-of-focus pic, you can see that the groove
  is nice and square. Now carefully work the new sealing ring onto the shaft and into its' groove.</p>

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• Here's the sealing ring in its' groove. Note the gap on the ring - that will close up when
  you put the shaft into the centersection.</p>

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• Install the new compressor housing and center cap O-rings (ignore the fact that my centersection
  is not clean, I did not install the O-rings, I sent it to Forced Performance without some of the parts
  installed to make disassembly for a thorough cleaning easier).</p>

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• After installing the small center bearing circlips (not shown, as I did not install them, due
  to the pending Forced Peformance work), place the compressor side brass bearing into the centersection.</p>

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• Place the thrust bearings' steel bushing onto the center bearing.</p>

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• Place the brass thrust bearing into the centersection over the steel bushing.</p>

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• Press the center cap into place and reinstall the circlip.</p>

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• Install the turbine side center bearing into place. Again, note that I did not fully clean the
  centersection, as I sent the turbo off to Forced Performance for a thorough cleaning, machining, reassembly,
  and balancing.</p>

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• Place the new heatshield on the centersection and carefully slide the turbine shaft through the
  center bearings.</p>

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• Carefully press the turbine shaft into the centersection. You will feel it "click" into
  place when the turbine shaft sealing ring compresses.</p>

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• Turn the centersection over and slip the compressor wheel onto the shaft. If you scribed marks
  on the shaft, wheel, and nut, now is the time to line them up. Then torque the nut to 70-78 in-lb.
  (not ft-lb.!!!). It might be best to use some blue threadlocker on this nut, even though most
  I've seen are self-locking.</p>

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• Place the centersection into the compressor housing, making sure to line up the locating dowel in
  the housing with the notch in the centersection.</p>

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• Install the compressor housing circlip.</p>

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Written by: VFAQ
Thanks: calesta