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/forums/showthread.php?4965-2.8TD-Turbo

followed a bunch of advice in this thread - http://www.nissanpatrol.com.au/forums/showthread.php?3146-RD28TD-Garrett-Turbo&highlight=compressor+backplate+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/eBayISAPI.dll?ViewItem&item=120639968678&ssPageName=ADME: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! :wink:

[brynk]

pulled off the dump pipe
7230

i then marked the centre, turbine & compressor positions
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my oiling problem is evident through the compressor... the question remains - is it coming from within the turbo, or up stream?
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7234

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.
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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 :rolleyes:
7237

[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
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the shaft
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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
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it took a torx bit to get these undone, sized t20
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the backing plate removed
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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
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[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
7259

everything you need
7260

all the parts of the turbo, in pieces
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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!
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the thrust plate from the turbo & the thrust plate in the kit - they look very similar... does anyone know if they're interchangeable?
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they line up really well!
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[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...
7366

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=270+degree+thrust+bearing+-+the+bearing+included+in+this+kit+is+a+360+degree+ type and a good info page on the whole biso:
http://autospeed.com/cms/title_Turbo-Bearing-Tech-Part-One/A_111628/article.html

thrust bearings side by side
7368
... 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
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the new journal bearing (left) vs the 'old' one (right)
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the compressor re-attached
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the turbine re-assy'd - note the lug ? marking the turbine side before disassy was redundant
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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!
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and everything i needed yesterday
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