areXseven

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I got started on this project about an hour ago and was able to take off all oil supply line and the water cooling lines. Then it was time to take off the 10mm bolts (6) that hold the Turbo onto the Manifold. Had to bang it a little for the Secondary Turbo to slide off. And it did! The big C-Clamp that holds the intake turbine and shaft assembly/compression turbine is going to be a Father Mocker to take off. I'll resume the rebuild tomorrow and post more photos. For now, I have to go feeds my little childrens and call it a night.

Here's a photo of the Turbos on the maniflold.(Pre-Rebuild)..

areXseven

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Here's the Secondary Turbo out of the Manifold. I can't wait to open the sucker up!! So far no major snags,...But the rebuild is young!!

areXseven

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Here's a close-up of the big C-Clamp that needs to come off in order to get acces to the Turbine Shaft and Seals...

areXseven

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Had to edit because of double post. Sorry.

areXseven

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CORRECTION. In my last few posts I made reference to the "big C-Clamp' that holds the Turbo housing halves together. That is a mistake. What I meant to say/write was big "Snap-Ring". Sorry for any confusion I caused. Thanks. -Jimmy

BoOsTin FD

Update? I like the pics so far

areXseven

iTrader: (1)

I'll post some more photos tomorrow. I would have finished with the rebuild tonight, but the snap-ring pliers I bought at A-Zone weren't the right size. I'll have to go to Sears tomorrow to get what I need in order to finish tomorrow evening.

It is really amazing how easy it is to do the rebuild. The most important part is making sure you mark the housing(s) and wheels before removal. The biggest PITA was removing the assembly off the Engine.

Anyway, thanks for your interest. If ANYONE needs photos of any specific part of the rebuild, just let me know. I can post any frame/photo of any part of the rebuild.

Just Bring It

I would like if you could post a picture of this Marking that you did. I have no idea what am i suppose to mark when taking them appart.

areXseven

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I'm about to post a few photos and I'll start with the one that answers your question regarding the marking of the Compressor-to-Bearing Housing. Thanks.

Marking the Compressor/Bearing Housing prior to disassembly is vital. The mark will get you back to the exact point and configuration of the Housings before the rebuild was started.

Here's a photo of where I placed my mark.....

areXseven

iTrader: (1)

The next step is to take the big snap-ring off the Compressor Housing. You'll need an extra large set of snap-ring pliers to accomplish the procedure. Once that's done, the Bearing Housing can be pulled out of the Comp-Housing.

This is a photo of the Bearing Housing after it was pulled....

areXseven

iTrader: (1)

Now the real fun begins.

In order to get to the internal components of the Bearing Housing, the Compressor Wheel will have to be taken off. BEFORE YOU DO THIS,..MAKE SURE YOU MARK BOTH WHEELS in relation to their location on the Bearing Housing. These marks will place the wheels back exactly where they were before they were taken off, which will keep the wheels/shaft balanced.

After making all the marks, you can start taking off the Comp-Wheel. This is done by taking off the Com-Wheel Nut. The Turbine Wheel (on the opposite end) has a built-in 12mm nut on the end that can be wrenched and held as you're taking off the Comp-Wheel Nut.

After the Comp-Wheel comes off, you'll have to twist and pull as it works it way out of the Shaft. After it comes off, the Turbine Wheel can be pulled out of the Bearing Housing from it's end. With that accomplished, it's now time to take off the Bearing Housing Cover. It will will have to be popped out with a punch. Once taken off, it will expose the Thrust Bearing and the Shaft Bearing.

Here's a photo that illustrates the parts after disassembly

areXseven

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I'll have to go tonight and buy a small Snap-Ring Pliers to get to the Turbine side Shaft Bearing. I'll post more photos late tonight or tomorrow of the completed Secondary Turbo Rebuild.

For now,...here's a photo of the components after I cleaned them up a little. The old Turbine Seal, which is installed right below the Turbine Wheel, was broken,.. as was the old O-Ring that goes between the Bearing Housing and Bearing Housing Cover. They may have been the culprits causing the Turbo smoking a little???

areXseven

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JUST A QUICK NOTE: I'm really having alot of fun doing the rebuld. The "MaxCoopers" and "Jimlabs" of this Forum could do this rebuild blind-folded (and probably in half the time it's taken me . Seriously, it's a real simple process. Anyone can do it.

More pictures tomorrow.

Just Bring It

Great pics Thanks a lot dude, You are the Man!!

areXseven

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I'll shoot and post a photo later this evening comparing the new & old Bearings with measurements taken with my Dial Calipers. The old bearings should show some wear. Additional photos of the rebuild will also be posted. Thanks.

zUMIEz

iTrader: (2)

Nice pics. Nice explanation. Nice graphics. Good job, man.

areXseven

iTrader: (1)

Crap!! I left the firewire at the office. I won't be able to down load any pics till tomorrow.

MakoRacing

iTrader: (12)

Id blow up my turbos some how if I tried to rebuild them...

areXseven

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LOL. Not as hard and complicated as it seems. The Turbos are probably one of the easiest engine components to work on.

alberto_mg

thanks for the write up and pics.

are you doing anything to fix cracks in the manifold that goes between the engine and the turbos?

areXseven

iTrader: (1)

No. I figure the crack(s) weren't causing any noticable problems, so why worry about it. The manifold didn't exhibit any signs of a leak (hot spot on the edge) and the gasket looks pretty clean.

BTW, I installed all the new parts (two Shaft Bearings and The Thrust Bearing w/ the Mating Ring) in the Bearing housing and installed the Turbine Seal on the Shaft. It's amazing how the Wheels/Shaft HAVE NO PLAY!! And they spin like a top. The I.D tolerance was .001 tighter in the new Bearings.

I put everything together except for the Bearing Housing Seal Plate which has a Seal that I'll have to press in.( Press??, ...I don't need no stinkin Press!! ). I plan on utilizing Maxcooper's way of pressing in the Seal using a small bolt, washers and a nut. I'll do that tomorrow evening.

Anyway, UPS tracking shows I'll recieve the other Rebuild kit on Friday, so I'll start to rebuild the Primary Turbo then and hopefully be able to slap them back on Saturday.

iceman4357

iTrader: (2)

you already have a DP? Even though you said you are not leaking i would get one to decrease temps to prevent further cracking

areXseven

iTrader: (1)

Yep. DP, MP w/ 3" Hi-Flow Cat, and Dual 3"' Exhaust MagnaFlow.

areXseven

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Wanted to show you guys a picture of the Seal Plate as it looks before it's taken off the Bearing Housing. The instructions provided in the Kit does not cover it's removal procedure and it does have to come off to get to the Thrust Bearing/Mating Ring and Compressor Bearing,.. not to mention the new Seal that has to be pressed on the Plate

Here it is attached....

Sorry, wrong photo. Let me try it again...

areXseven

iTrader: (1)

There is a punch hole located on the back of the Bearing Housing. In the attached photo it can be seen at the 12:00 position. The Seal Plate is removed by punching it out through the back of the B-H.

There was alot of gunk and scale on the Trust bearing. I don't think these Turbos had ever been rebuilt. The Mating Ring also showed signs of wear. The O-ring was totally pressed flat and was so toasted that it busted as I tried to extract it from it's groove.

The Thrust Bearing is attached with 3 Hex screws size .20. The new Hex screws supplied with the kit are size .15

Here's a photo....