rd28tdi turbo rebuild

[brynk]

g'day all

talked about a problem with gusty's turbo in this thread, where i can see oil collecting from the turbo through the intercooler to the intake - http://www.nissanpatrol.com.au/forum...65-2.8TD-Turbo

followed a bunch of advice in this thread - http://www.nissanpatrol.com.au/forum...center+housing

well i bit the bullet & bought a kit off ebay; kit arrived in a timely manner, but some questions remain as to the correctness (more to follow) - http://www.ebay.com.au/itm/ws/eBayIS...E:L:OU:AU:1123

at the moment, the turbo is in pieces soaking in petrol, and i'm wondering if i haven't just invested my saturday pulling apart a perfectly good turbo!

[brynk]

pulled off the dump pipe
01-turbine.jpg

i then marked the centre, turbine & compressor positions
02-centre-turbine-housing-marked.jpg
03-compresr-housing-backing-marked.jpg

my oiling problem is evident through the compressor... the question remains - is it coming from within the turbo, or up stream?
04-compressor-oiling.jpg
05-compresr-wheel.jpg

separating the turbine housing from the centre housing turned into a kharnarva - i flogged it for a while with rubber mallet, timber mallet, hardwood & in the end i settled on flogging the cast mounting point for the oil/water supply with a softish steel chisel. my vice isn't mounted rigidly so i wasn't too concerned about cracking.
06-separate-turbine-housing.jpg
07-turbine.jpg

before removing the retaining nut, i marked the shaft. in retrospect, this will get the nut aligned nicely to the wheel, but that's about it
08-comprs-shaft-marked.jpg

[YNOT]

Have a close look at the inside of the air ducting that runs between the air filter and the turbo inlet, look for a coating of oil that starts where the PCV hose connects in.

Tony

[brynk]

more evidence of oiling in the compressor
09-more-compresr-oiling.jpg

the shaft
10-shaft.jpg
11-shaft.jpg

the journal bearing - oddly, there was no retaining clip or equivalent... ? edit: yes there was (and had to be!)... i just couldn't see it for the shyte
12-shaft-bearing.jpg

it took a torx bit to get these undone, sized t20
13-thrust-plate-torx20.jpg

the backing plate removed
14-compresr-side.jpg

the underside of the thrust plate that retains the floating part of the bearing - when these galleys fill up under oil pressure, the shaft spins on a soft pillow of hot oil... well that's my theory anyway
15-compresr-side-plate-flipped.jpg

[brynk]

thanks tony - there is definitely oil in the pcv line - when i disconnected it there was a couple of drips in the small hose

by the same token, there is a fair whack of black smoke on accel & start which is a newish thing.

[YNOT]

Black smoke is unburnt fuel, oil smoke is blue.

Tony

[brynk]

closer look
16-journal-bearing-removed.jpg

everything you need
17-everything-needed.jpg

all the parts of the turbo, in pieces
18-turbo-bits.jpg

all the new bits in the kit with the old bits lined up next to them... there's a few extras which may or may not be a concern!
19-kit-bits.jpg

the thrust plate from the turbo & the thrust plate in the kit - they look very similar... does anyone know if they're interchangeable?
20-questionable-part.jpg

they line up really well!
21-questpart-aligns-well.jpg

[brynk]

tony thanks again - i had wondered if diesels behaved the same ;

is there a method i can follow to check the timing of the fuel pump ?

[YNOT]

tony thanks again - i had wondered if diesels behaved the same ;

is there a method i can follow to check the timing of the fuel pump ?

There is but you will need special tools and a dial gauge to do it. I would need to go looking to find what the specs are.

Tony

[brynk]

i received a timely answer from the bloke i bought the kit off regarding my questionable thrust bearing, which gave me the confidence to proceed with re-assy.

i can say from my experience that this bloke's service [globalautoco on ebay] was commendable.

everything cleaned up & ready to go back together...
22-cleaned-up.jpg

the thrust bearing i received in the package was a 360degree bearing surface (right, bronze), where as the bearing that came out of the turbo was a 270deg bearing surface (left, steel)

here is a google search on it all - http://www.google.com.au/search?q=27...60+degree+type and a good info page on the whole biso:
http://autospeed.com/cms/title_Turbo...8/article.html

thrust bearings side by side
24-360vs270-underside.jpg
... looking closely in this shot you can see a tiny galley drilled into the focal point of the oil channel

and the new thrust bearing, centre-side up, showing the oil channel; and then assembled
23-350deg-thrust-bearing.jpg
26-360deg-thrust-inst.jpg

the new journal bearing (left) vs the 'old' one (right)
25-journal-bearings.jpg

the compressor re-attached
27-compressor.jpg

the turbine re-assy'd - note the lug ? marking the turbine side before disassy was redundant
28-turbine-guide-lug.jpg

the compressor housing bolt holes are drilled through the housing wall into the chamber - i didn't notice this before it was cleaned up for all the shit!
29-compresr-housing-bolt-holes.jpg

and everything i needed yesterday
30-drawn-together.jpg