Do-it-yourself turbine repair | Worth a try?

Failures of a diesel engine turbine, despite the 10-year service life declared by the manufacturers, are quite common. At the same time, the performance of the motor depends on the functioning of this structural element. From this we can draw the following conclusion:

• The turbine requires regular maintenance.
• Turbine design

The turbine housing installed together with the diesel engine is made of cast iron. During active use of the vehicle, the beds located under the bearings, as well as the sealing ring sockets, often fail.

The turbine itself looks like a snail shell. The compressor moves through a shaft on which the impeller is mounted. The first is made of an aluminum alloy, characterized by increased resistance to heat, and the second is made of medium-alloy steel. Due to the design features of both elements, in case of breakdown they are replaced with new ones.

The turbine has a rather complex shape. Exhaust gases are supplied through its internal part, pumped by a compressor, due to which the initial engine power is increased.

Signs of trouble

Manufacturing a turbine is a rather labor-intensive process, despite the apparent simplicity of its design. Manufacturers of the unit have to measure its dimensions to fractions of a millimeter.

Before repairing diesel engine turbines, it is necessary to carry out preliminary diagnostics.

Any errors during the restoration of the TCR lead to a sharp increase in the cost of work due to the high cost of the unit. To identify faults and eliminate them, you will need the help of an experienced specialist. However, you can diagnose the motor yourself. The following signs of turbine malfunction may indicate problems with the engine:

1. Exhaust gases have acquired a black, bluish or bluish tint.
2. The motor began to make a lot of noise in different operating modes.
3. The engine temperature regularly reaches high levels (overheating is observed).
4. The power plant began to consume noticeably more fuel and oil.
5. The appearance of clear pops while the engine is running, a whistle or a dull hum.
6. Reduced vehicle dynamics due to decreased traction levels. At low speeds the power unit is unstable.
7. Oil smell appears.

What will be needed for repairs

Repairing a diesel engine turbine on your own requires tools, spare parts and advanced plumbing skills. In their absence, it is cheaper to turn to professionals. Assembly in artisanal conditions can lead to grains of sand getting into the unit. As a result, it will completely fail. If you are confident in your abilities, you can start working.

Before repairing the turbine, you should prepare a repair kit. You will need the following parts:

• set of inserts;
• oil seals;
• screws;
• screws;
• washers.

You will also need the following set of tools:

• socket and open-end wrenches;
• screwdrivers;
• nippers with sliding jaws;
• figure editing;
• puller;
• mallet.

This is enough to restore the turbine with your own hands.

Causes of breakdowns

Turbocharger malfunctions occur for a number of reasons.

Most often, diesel engine and turbine breakdowns occur due to untimely oil changes.

Long-term use of old lubricant or the ingress of water or fuel into it leads to rapid wear of the bearings, blockage of the oil channels or damage to the axle. The faulty element must be replaced. It cannot be repaired. The described consequences result from using too thick oil.

The second most “popular” cause of problems with a turbocharger is a decrease in pressure in the oil hoses caused by improper installation of these elements or the turbine itself. This problem can lead to rapid wear of the rings, shaft journal, and bearings.

It is important to note: running a diesel engine for 5 minutes without oil causes serious and irreparable damage to the power unit.

We should also not forget that foreign objects can get into the turbocharger. Their appearance in an operating turbine leads to breakdowns of the wheel and rotor blades, which reduces the level of pressure generated.

What are the types of turbocharger malfunctions and how to recognize them?

The main signs of a malfunctioning turbine are a sudden drop in the power of the vehicle's power plant, increased oil consumption, a change in the sound of the engine and turbocharger, and blue or black exhaust gases.

Any of these signs indicate that it is time to check for a turbine repair kit. It is necessary to find out whether the turbocharger is working properly, and also be sure to check the operation of the engine and other components of the machine. These recommendations should not be ignored, since a car’s power plant with normal operation and quality maintenance is the key to stable operation of the turbocharger for a long time.

Turbine repair

It is recommended to have your engine repaired at a specialized station. However, you can troubleshoot some problems yourself.

First, you need to visually inspect the turbine and evaluate its operation. Do-it-yourself turbine repair begins with checking the oil level and its quality. In addition, the likelihood of foreign objects entering the structure should be assessed.

If these reasons have been excluded, then you can begin to analyze the color of the exhaust. A change in color, as well as a decrease in thrust, often indicate problems with the intake or exhaust. In the first case, we are talking about a decrease in the volume of supplied air, in the second – about the presence of leaks.

To check the operation of the turbine, you need to start the engine. The power unit should not make any extraneous sounds such as creaking or whistling. In a working engine with a turbine, air does not escape from the connections. Next you need to check the condition of the air filter.

Basically, problems with the functioning of the intake and exhaust arise precisely with this element. If the filter looks normal, then next you need to check the oil drain line. It often develops kinks, damage or plugs.

Next comes the turn of the rotor. It needs to be rotated several times around its axis.

If the rotor clings to the turbine housing, it must be repaired.

When the engine makes a lot of noise during operation, you should check:

1. All pipelines to identify their wear.
2. Turbine axis.
3. Rotor.

If there are problems with any of the described structural elements, qualified repairs of the engine and turbine will be required.

The presence of malfunctions may be indicated by incorrect operation of the supercharging system. To check the latter, you will need outside help. First of all, you should find the pipe that connects the turbine and the intake manifold. Then you need to start the engine and clamp the specified pipe by hand.

At the same moment, the second person should press the gas pedal and hold it for 3 to 5 minutes. A working pipe responds to such driver actions by inflating under pressure. The described experiment must be repeated 3-4 times. If in none of the cases does the pipe inflate, then the turbine is faulty.

Regardless of what “symptoms” appear that indicate problems with the supercharging system, it is recommended to carefully inspect the pipes, flanges, manifolds and other engine elements for cracks.

Repair technology

After successful dismantling of the turbine, a thorough inspection of all its structural elements begins. This is one of the most important stages of repair, regardless of the model and condition of the unit.

Be sure to inspect the impellers of the turbine and compressor parts of the turbine. In the absence of any visible mechanical damage, it is recommended to simply clean them using fine sand. It is advisable to additionally use small glass beads.

When repairing a diesel engine turbine with your own hands, you can identify other defects that require a specific approach to elimination.

Replacement of various diesel engine turbine components

Damaged compression wheel blades

Experts do not recommend repairing blades; this will not lead to the desired result. You should not try to align or solder them yourself. It is advisable to purchase a new part from the store, which will have a better effect on the functioning of the engine.

Experts recommend additionally replacing the air filter. Check the intake manifold to determine its tightness and absence of damage.

Compression wheel blade design

Presence of defects on the turbocharger wheel

If there is damage to this part, it is advisable to replace it immediately. Otherwise, it will not be possible to guarantee efficient engine operation.

Turbocharger wheel

Defects on other small parts

When repairing a diesel engine turbine with your own hands, you must check the condition of other structural elements - bearings, bushings, rings. If defective parts are identified, they are replaced. It is advisable to install a new shaft.

Turbine assembly

When the repair of the diesel turbine is completed, we begin to assemble it. Internal retaining rings are installed into the cartridge. When installing them, you need to make sure that they fit tightly into their sockets. After this, they proceed to installing the turbine liner. It is pre-lubricated with engine oil. After fixing all structural elements, the compressor liner is inserted.

When the oil treatment of the bushing is completed, install all the plates, bolts, and oil scraper. Oil scraper rings are installed on the shaft. The snails are inserted into place, not forgetting the valve.

Stages of diesel engine turbine repair

Related video: All the secrets when repairing a turbine

Preventing turbine malfunctions

To increase the life of the turbine, you need to follow a few simple rules:

1. Use only high-quality oil and fuel.
2. Avoid quick turbine flushes. This procedure can completely disable the unit at once.
3. Change air filters promptly.
4. The oil must be changed after every 7 thousand kilometers.
5. Be sure to warm up a car with a turbocharged diesel engine.
6. At the end of a long trip, the car should idle for three minutes. This will prevent the appearance of carbon deposits.
7. Regular diagnostics of the power plant.

Self-installation of a turbocharger

Despite the complexity of repairing a turbocharger, there are operations that the owner, with the proper technical skills, can perform independently. We are talking about dismantling and installing the unit. In this case, you should follow some rules to avoid trouble.

• Before installing a repaired turbocharger, thoroughly rinse the oil supply pipe, since the health of the unit directly depends on the oil supply to it. In addition, after repairs, remaining dirt can get inside the unit and initially damage it. In general, when working with a turbine, maximum cleanliness and accuracy should be observed. Before installing the TC on the engine, about 20 g of oil should be poured into the receiving hole, after which it is necessary to rotate the shaft several times to distribute it evenly. You definitely need to change the oil, oil and air filters.
• It is prohibited to use sealants when installing pipes through the gasket. Only new, good quality gaskets should be used. After assembly, you need to start the engine and let it idle for 10-15 minutes. In this case, you need to make sure that there are no oil or coolant leaks through the connections. The turbine running-in period is 1000 kilometers. In this case, you should not exceed the speed above 100 km/h, and also avoid sudden changes in driving modes.

Do-it-yourself repair of diesel engine turbines

Author:

Maxim Markov

The effectiveness of a turbocharger when installed on an engine is beyond doubt. The power and torque of the motor increases significantly. Long-term operation and untimely maintenance eventually lead to the need to repair diesel engine turbines. But before carrying out such maintenance, you should remember the structure of this unit and correctly diagnose a violation of normal operation.

Turbine lifespan on diesel engines: opinion of car owners

• Still alive
  “Judging by reviews of the repair of diesel engine turbines from most car owners, the operating rules are as follows: fill in high-quality lubricant and change it on time, adhere to the correct cooling mode when stopping. Then, throughout the entire service life, repairs to the turbine on a diesel engine will not be required. My car has 147,000 km on it, and the turbocharger was and is in perfect condition.”
• The resource is no less than that of the engine itself
  “I drove 226,000 kilometers on my two-liter Audi TDI. Not long ago I carried out a technical inspection; the turbine is original and works flawlessly. Servicemen reported that the service life of the turbocharger is exactly the same as that of a diesel engine. Moreover, the variator will last just as long. Germany has always made and will continue to make durable cars. After all, they have experience and a good brand reputation.”
• Much depends on the fuel
  “I had the opportunity to observe engines that have driven more than 200,000 kilometers. However, their owners take care of their cars, fill them with additives, use only high-quality fuel, and generally know these engines like the back of their hand. I believe that if the fuel is good, then everything will be fine with the car. But if you fill it with low-quality diesel fuel once, the mechanism will break.”
• Mileage doesn't say much here.
  “How does a turbine operate on a diesel engine? Imagine that you woke up a sleepy sprinter and forced him to run; he is unlikely to be the first to reach the finish line. And after running, his breathing will not immediately calm down. It's the same with a turbocharger. No matter how much you drive the car, it does not affect the performance of the turbine in any way. I had a car with a mileage of 240 kilometers, but the pressure in the turbine was normal, we were convinced of this when we took measurements at a car service center.”

• You can easily ruin a new one
  “Are you going to buy a used car or a contract turbocharger? There is no guarantee that repairs will not be required. Even if the engine and turbine are new, everything can be broken within a day. Moreover, it will no longer be possible to restore the power unit. Here you don’t even need to drive a car in extreme mode. Just turn off the engine incorrectly or turn off the ignition a couple of times if the engine is not running at XX speed, but much higher.”
• It's all about care
  “On my car, the turbocharger is cooled using antifreeze, and the mechanism is covered with a protective casing, and there is electrical control. I think that the turbine will serve for a very, very long time. I have already ridden 180,000 km without any problems. The blades are as clean as the first snow. The whole secret is in proper care."

Turbine purpose and resource

The operation of a turbocharger is aimed at increasing the flow of supplied air into the combustion chamber.
This leads to more complete and rapid combustion of fuel, resulting in greater efficiency from the engine at the required operating conditions. Designers do not have to increase the engine displacement and carry out complex technical upgrades. Turbocharging is used both on diesel engines and gasoline units. In this case, diesel engines demonstrate greater efficiency. This is due to the high compression ratio of the diesel fuel unit and the lower number of revolutions during operation. Recently, a gas turbine engine, which has already been developed for tractors and trucks, has been called promising.

Given the high repair costs, owners strive to keep the turbocharger operational for as long as possible. Increasing the service life is directly related to understanding the operating features of the turbine supercharger. The impeller starts working from the first seconds of starting the engine, and stops a few seconds after the crankshaft stops. At low engine speeds, the exhaust gas pressure does not allow the turbine to spin. Switching on occurs with increasing speed, and the engine seems to get a second wind.

Initially, the service life of the supercharger is not inferior to that of the engine itself. Premature turbine failure is associated with high temperature loads and high rotation speeds.

Description of the turbocharger design - nuances

One of the common mistakes regularly made by those who decide to independently repair a turbocharger is associated with a misunderstanding of the damping effect inherent in the design of the bearing unit of the unit. It is this question that requires some clarification, since misunderstanding can lead to dire consequences.

The need for damping is related to the operating characteristics of the engine. The exhaust gases enter the exhaust manifold and then onto the turbine impeller in portions in accordance with how the engine exhaust valves open. Thus, the flow is not uniform - its effect on the turbine rotor is of a pulsed nature. To compensate for the impact, it would be necessary to give the rotor much greater rigidity, which would lead to an increase in the size and weight of the entire unit. A solution was found in the form of using floating bushings in sliding bearings, which perform a damping function on the housing side.

There is a certain gap between the floating bushing and the housing, in which an oil film is formed, almost identical to that formed between the rotor and the bushing. The bushing rotates at a frequency approximately half the rotor speed, and two oil films successfully compensate for the pulsed effect of exhaust gases on the turbine rotor, performing shock-absorbing functions.

When independently repairing a turbine, an allegedly increased play between the bushing and the housing can be diagnosed; this is taken as a defect, after which bushings are machined from the appropriate material (usually bronze), which are pressed into the housing with some interference. The analogy is obvious - these bushings resemble the bushings in the connecting rod head or in the starter, but this error leads to dire consequences. The turbine operates at extreme conditions, and the absence of one oil film leads to a decrease in the damping effect, which causes the wear of the plain bearings to increase many times over. In extreme cases, the rotor shaft may even break.

Design features

To understand possible failures, one should also recall the design of the turbine used with diesel engines. The turbocharging system includes:

1. Compressor impeller.
2. Supercharger impeller.
3. Support shaft.
4. Bearing assembly.
5. Lubrication fitting.
6. Boost pressure control regulator.

When the turbine operates, the air heats up, which leads to an increase in its density. Therefore, it is necessary to turn on the cooler (intercooler) to return the parameters to normal.

Sliding bearings receive the greatest impact in operation, taking into account the high rotation speed. Therefore, the importance of maintenance in terms of timely oil changes is very high. By the way, engine oil for a diesel engine with a turbine should be selected only taking into account the manufacturer’s recommendations.

Other reasons that disrupt the normal operation of the turbine include a sharp start on a cold engine, stopping the engine after an intense rhythm without waiting to idle.

What is needed to restore a turbocharger

If the car owner is confident in his capabilities, then the following devices will be useful for the turbocharger restoration procedure:

• Inserts of several sizes;
• Oil seals;
• Rings;
• Screws;
• Washers;
• Screws;
• Spare earbuds;
• Socket and open-end wrenches;
• Screwdrivers;
• Mallet;
• Puller;
• Figure swimsuit;
• Nippers with sliding jaws.

It is easier to disassemble iron than to assemble it. It is advisable to designate all the fastening points of the turbine elements and their location relative to each other.

To understand possible failures of the mechanism, you should first study the design of the diesel engine turbine. The turbocharging system includes:

• Compressor impeller;
• Supercharger impeller;
• Support shaft;
• Bearing assembly;
• Lubrication fitting;
• Boost pressure control regulator.

Possible malfunctions and their diagnosis

1. Engine oil leaks and gets into the air entering the cylinders.
2. Air leaking through the pipe seals, loss of power.
3. Clogged supply and discharge oil channels.
4. The appearance of cracks or deformations of the turbine housing or parts.
5. Insufficient air flow through the air filter.

It is easier to detect malfunctions of a diesel engine turbine at the initial stage by analyzing the exhaust gases. Their color allows you to preliminarily determine a possible deviation:

• a blue tint indicates oil droplets entering the air;
• White smoke will indicate that the oil discharge channel is clogged;
• black smoke indicates a lack of air in the cylinders, i.e. about the leak.

Additional signs of turbine malfunction are expressed in the loss of dynamic characteristics of the machine. An imminent breakdown also means the appearance of extraneous noise in the operation of the turbine. This may be due to wear of bearings, deformation of the housing and moving parts.

When the first signs appear, do not immediately rush to paid diagnostics. It is not difficult to check the operation of a diesel engine turbine with your own hands. First of all, taking into account the symptoms, we check the engine oil level. If the level decrease is more than 1 liter per thousand km, then we analyze the color of the exhaust.

When white and bluish smoke is detected, the question of how to check a turbine on a diesel engine is solved using the following algorithm:

1. Recall when the air filter was last replaced. If air flow is poor, a pressure difference occurs between the bearing block and the housing. Oil begins to penetrate into the turbocharger housing. This is the cause of the blue smoke. If the filter is clean, move on to the second stage.
2. Checking the oil outlet channel. The presence of bends, cracks or a regular plug makes the oil removal circuit from the turbine faulty. In some cases, it is enough to clean the channels, and their normal condition will lead to the restoration of all indicators. Another reason for this behavior of the turbine is a violation of normal ventilation of crankcase gases. You can't do this without the help of a mechanic.
3. At the next stage, the condition of the mechanical parts of the turbine is checked. The axial play is checked, which contributes to the possible contact of the impeller with the turbine walls. Any nicks or abrasions require immediate removal. Here, the question of how to check a diesel engine turbine will only be answered by a specialized service center.

When eliminating play, fine adjustment is required. For example, the axial displacement of the shaft should not exceed 0.05 mm, and the radial play is allowed at a maximum value of 1 mm. Agree that adjustment is possible only after replacing worn parts using special instruments.

Timely detection of abnormalities in operation will help to avoid costly repairs. It is likely that with early diagnosis of faults, their elimination will be achievable by flushing and replacing consumables.

Diagnostics of a turbine on a car consists of 12 stages

• Test drive a car with a master
• Reading parameters with a diagnostic scanner, identifying error codes in the car’s electronic units
• Checking the turbine for play
• Checking the condition of the impeller for damage
• Checking the operation of the turbine actuator
• Checking the operation of the variable geometry mechanism
• Checking the operation of the wastegate valve
• Checking the tightness of the air supply system
• Checking the tightness of the vacuum system
• Checking the engine oil level
• Checking the operation of the EGR system
• Checking the temperature

Lada 21099 turbo PROJECT ORIGIN › Logbook › DIY turbine (turbocharger) repair

Before repairing the turbine, it is necessary to carefully inspect it from the outside in order to identify the presence of all components, external defects and deformations.

Then both “snails” are removed from the turbine and the condition of both impellers is visually determined. Quite often, impellers have physical damage that is visible to the naked eye. Such damage immediately indicates that turbine repair is inevitable. If the turbine drives oil

Then, all components of the turbine are examined to determine the suitability of each part for restoration. Parts found to be unsuitable must be replaced with new ones.

Repair of turbines of diesel and gasoline engines is basically no different and occurs in several stages:

After this, the parts that have undergone shot blasting are washed again to wash off and completely remove any solid particles that may remain on the parts. Numerous damage to the compressor wheel blades.

In addition to visually visible damage to the impellers, the main damage is damage to the support bearings, retaining rings, bushings and the shaft itself. Typically, these damages occur from a lack of oil supply to the working surfaces during turbine operation or the use of non-recommended oils. Increased wear of the shaft journal.

Cause: The quantity or pressure of oil supplied to the TKR is less than required. During repairs, you may have to replace the shaft with a new one. In most cases, the shaft does not change. Significant uneven wear of the shaft journal.

Cause: Dirty oil. When repairing, it is necessary to replace the shaft with a new one. Significant uneven bearing wear.

Cause: Dirty oil. During repairs, all bearings are replaced with new ones. Burnt oil in the oil passages of the bearings.

Reason: Engine overheating or sudden engine shutdown, poor quality oil. During repairs, all bearings are replaced with new ones. Starting to repair the turbine yourself.

The turbine shaft is then measured for wear. If the wear of the turbine shaft is within normal limits, then it is sent to a special turning and grinding machine, where it is ground to repair size. The groove of the locking ring is straightened on a special machine. Then the balancing process occurs. It consists of two stages. First, the turbine shaft is balanced in two planes of the turbine wheel. After this, bushings and a compressor impeller are installed on the shaft and, in this form, it is again sent for balancing. Balancing the turbine on a stand.

There are separate specialized stands for balancing turbines for trucks and cars.

During balancing work, special balancing marks are applied along which the turbine “cartridge” is assembled. In principle, the result is an assembled turbine only without the “snails”.

The cartridge assembled in this way is sent for testing to a balancing stand, where compressed air is supplied to the “cold” impeller and the turbine is spun up to 5,000 rpm.

If all turbine parameters are normal, then “snails” are screwed to the cartridge.

Operating principle and little-known nuances

It would seem that the principle of operation of a turbocharger is not particularly complicated. Exhaust gases from the car's power unit spin the turbocharger impeller, which converts the kinetic energy of the gas flow into mechanical energy. Using a pump, fresh air is supplied to the compressor through a filter device and, after compression, enters the car engine. Using this process, it is possible to increase the efficiency of the power plant by 20-25 percent by increasing the efficiency and rate of fuel combustion.

The damping effect and the consequence of its misunderstanding

One of the “pitfalls” for those who decide to undertake repairs is a lack of understanding of the damping effect, which is closely related to the design features of the bearings of the turbocharger. This issue needs to be considered in more detail, since repair work without understanding it often leads to disastrous results.

The design of the turbine initially provides for the need for damping due to the operating characteristics of a car engine. The exhaust passes through the exhaust manifold and enters the turbocharger impeller in jerks, rather than gradually, in proportion to the opening of the power unit valves. It turns out that the gas flow is non-uniform and affects the turbocharger impeller with impulses.

To compensate for such a heterogeneous effect, it would be necessary to design a rotor of increased rigidity, which would result in an increase in the mass and dimensions of the device. The problem was solved by bushings installed in the bearing assembly, which created a damping effect on the volute side.

It's quite simple to explain. The diameter of the bushing is chosen such that there remains a small distance between it and the volute, allowing an oil film to form during operation, almost the same as that formed in the gap between the bushing and the shaft. The rotation speed of the sleeve is approximately half the speed of the shaft, and a pair of oil films makes it possible to successfully absorb uneven exhaust pressure on the turbocharger rotor.

When repairing a turbocharger on your own, it may seem that there is excessive play between the cartridge body and the bushing. Most car enthusiasts will consider this effect to be a malfunction and will begin to grind out a new bushing (usually bronze) and press it in quite hard during installation. This is usually done by analogy with the bushings that are installed on the starter or connecting rod head, but in this situation such an understanding will cause disastrous results.

The turbine rotates at a very high speed, the disappearance of the second oil film will reduce the damping effect by almost half, which, in turn, will cause rapid wear of the bearings. Sometimes in such cases, due to impulsive load, the rotor shaft may even break.

Imbalance

In order for the rotating part to work as correctly and as long as possible, it is balanced. The most common example in this area is the process of wheel balancing, which is carried out constantly after repair work affecting the wheels and chassis of the vehicle. If this procedure is not followed, considering the front wheels, runout will be propagated through the steering system. And in the version with rear wheels, even without any pronounced signs of imbalance, the tires may wear out prematurely, which will be visible by special spots. Do not forget about the increased load and accelerated wear of suspension elements.

Of course, the turbocharger impellers are much smaller than the diameter of the wheels, but we must not forget about the rotation speed, which is many times higher for the turbocharger rotor and averages 100,000 rpm, and in some models reaches 300,000 rpm. Who remembers physics, the load on a rotating element increases in proportion to its speed squared. So, if we take into account the high rotation speed, the loads on the turbocharger rotor and the car wheels are quite comparable, and lack of balancing often causes serious damage.

Dismantling a bearing assembly or changing the pressure of the bolts that secure it sometimes causes imbalance. Hence the obvious conclusion is that in “home” conditions it is impossible to balance the rotor, despite the correct replacement of all damaged elements. Accordingly, such repair work becomes pointless, because a turbine with an imbalance will again very quickly stop working.

The turbocharger rotor is balanced on special equipment by experienced craftsmen in several stages. First of all, the rotor itself is balanced, then the cartridge is assembled and the entire assembly is balanced. Specialists use two different devices for this process, one of which makes it possible to recreate the operation of a turbocharger under conditions close to real ones: pressure is created on the rotor, and oil of the required temperature is supplied to the bearing assembly.

Let us note once again that it is impossible to balance a turbocharger rotor at home. Despite the technically correct replacement of all necessary elements and correct installation, the turbine will still be unbalanced, and obviously this will quickly cause its failure.

We repair the turbine with our own hands

For many car enthusiasts who love power and speed, the issue of buying a car with a turbocharged engine is very important.

In turn, the task of a turbocharger is to supply a larger volume of air to the engine cylinders and, as a result, increase the engine’s power.

The only drawback of such a useful element is its frequent failure, so every car enthusiast should be able to make at least minimal repairs to the turbine.

How to balance a turbine

Balancing a car turbine rotor is carried out using special equipment by a qualified specialist, and this process takes place in two stages. First of all, it is necessary to balance the rotor itself, after which the cartridge is assembled and the entire assembly is balanced. For this, two different machines are used, and on the second one the operation of the TC in real conditions is simulated, oil of the required temperature is supplied to the bearings and loads are created on the rotor.

It is worth repeating once again - in artisanal conditions, balancing a turbine rotor is impossible in principle. And even if all the necessary parts were replaced and the assembly was carried out correctly, such a unit will have an imbalance, which will lead to its rapid failure.

Design features of the engine turbine

Structurally, a turbocharger is a very simple mechanism that consists of several basic elements:

1. Common body of the assembly and cochlea;
2. Sliding bearing;
3. Thrust bearing;
4. Spacer and thrust bushing.

The turbine housing is made of aluminum alloy, and the shaft is made of steel.

Therefore, if these elements fail, the only correct solution is replacement.

Most turbine damage can be easily diagnosed and repaired. In this case, the work can be entrusted to professionals in their field or you can do everything yourself.

In principle, there is nothing complicated about this (we will look at how to dismantle and repair a turbine in the article).

Studying the mechanism

A turbine is an impeller that is mounted on a shaft through which the compressor moves. The body is made of heat-resistant aluminum alloy, and the shaft itself is made of steel with medium alloy properties. Since these parts cannot be repaired, if they fail, they are replaced with new parts.

During active operation, wear may occur in the area under the bearings and the O-ring seats. The turbine casing and volute are cast from cast iron. Thanks to its complex shape, gases flow, causing the entire unit to move.

Main malfunctions and their causes

As operating practice shows, there are two main causes of breakdowns - poor quality or untimely maintenance.

If a technical inspection is carried out according to plan, the turbine will operate for a long time and without any special complaints from motorists.

So, today we can identify several main signs and reasons for turbine failure:

• 1. The appearance of blue smoke from the exhaust pipe when the speed increases and its absence when the norm is reached. The main reason for this malfunction is oil getting into the combustion chamber due to a leak in the turbine.

• 2. Black smoke from the exhaust pipe indicates combustion of the fuel mixture in the intercooler or injection line. The probable cause is damage or breakdown of the TKR (turbocharger) control system.

• 3. White smoke from the exhaust pipe indicates a clogged turbine oil drain line. In such a situation, only cleaning can save you.

• 4. Excessive oil consumption up to one liter per thousand kilometers. In this case, you need to pay attention to the turbine and the presence of leaks. In addition, it is advisable to inspect the joints of the pipes.

• 5. The dynamics of acceleration are “dulled”. This is a clear symptom of lack of air in the engine. The reason is a malfunction or breakdown of the TKR (turbocharger) control system.
• 6. A whistle appears when the engine is running. The probable cause is an air leak between the engine and the turbine.
• 7. A strange grinding noise during turbine operation often indicates the appearance of a crack or deformation in the unit housing. In most cases, with such symptoms, the TCR does not “live” for a long time and further repair of the turbine may be ineffective.

• 8. Increased noise during turbine operation can cause clogging of the oil line, changes in the rotor gaps and the latter touching the turbocharger housing.
• 9. An increase in exhaust toxicity or fuel consumption often indicates problems with the air supply to the TCR (turbocharger).

Device

In order to repair a KamAZ turbine with your own hands, you need to study its structure. Despite the apparent complexity, the node configuration includes only three main parts:

1. Turbine block (exhaust gas side).
2. The compressor responsible for the boost.
3. Intermediate cartridge (bearing unit).

The cartridge aggregates with a rotor shaft, which is connected together with a turbine wheel. The compressor analogue is fixed separately on the shaft. The unit is equipped with an adjustment system, which is located on the turbine or compressor housing, depending on the modification of the unit. This device is responsible for the operation of the bypass valve. The cartridge has seals that prevent oil from entering the housing parts.

Features of turbine dismantling

To repair the turbine yourself, it must be dismantled.

This is done in the following sequence:

• 1. Disconnect all pipelines that go to the turbine. In this case, you should be extremely careful not to damage the unit itself and the devices adjacent to it.

• 2. Remove the turbine and compressor volutes. The latter can be dismantled without problems, but the turbine scroll is often attached very tightly.

Here, dismantling can be done in two ways - using a mallet method or using the volute mounting bolts themselves (by gradually releasing them from all sides).

When performing work, you must be very careful not to damage the turbine wheel.

• 3. Once the work of dismantling the scrolls is completed, you can check for shaft play. If the latter is missing, then the problem is not in the shaft.

Again, a small lateral play is acceptable (but not more than one millimeter).

• 4. The next step is to remove the compressor wheels. To perform this job, pliers will be useful. When dismantling, keep in mind that the compressor shaft in most cases has a left-hand thread.

To remove the compressor wheel, a special puller is useful.

• 5. Next, the sealing liners are dismantled (they are located in the recesses of the rotor), as well as the thrust bearing (it is secured with three bolts, so there are no problems with removal).

• 6. Now you can remove the liners from the end part - they are secured using a retaining ring (sometimes you have to tinker during dismantling).

The plain bearings (compressor side) are secured with a retaining ring.

7. When performing dismantling work, it is necessary (regardless of the breakdown) to thoroughly rinse and clean the main elements - the cartridge, seals, rings and other components.

Causes of turbine failure

If the maximum pressure of the turbocharger is missing, this may mean that it has failed. Since a new turbine is considered an expensive part, you can do the turbine repair yourself. Failure can occur for various reasons:

• clogging of the catalyst, which ultimately creates back pressure;
• incomplete closing of the bypass valve;
• leak on the internal path;
• clearance in the area of ​​the turbine supercharger;
• wear of the impeller during rotation.

Depending on the specific type of breakdown, you should take the right approach to repairing a diesel turbine with your own hands. Most reasons result in the turbine not being able to build up enough pressure to operate successfully. If the cause of the failure is play, this is a serious problem. You can only replace a part yourself if you have special skills and suitable tools.

Repair features

Once dismantling is completed, repairs can be made. To do this, you should have a special repair kit on hand, which contains everything you need - liners, hardware, seals and rings.

Check the quality of fixation of the nominal liners. If they are loose, then they need to be sharpened and the shaft balanced.

In this case, it is advisable to clean the liners well and lubricate them with engine oil.

The retaining rings located inside the turbine must be installed in the cartridge. At the same time, make sure that they are in their place (in special grooves).

After this, you can mount the turbine liner, having previously lubricated it with engine oil. The liner is secured with a locking ring.

The next step is to install the compressor liner, after which the well-lubricated sleeve can be inserted.

Next, put the ring plate on it and tighten it thoroughly with the bolts (without fanaticism).

Install the skid plate (secured with a retaining ring) and oil scraper ring.

All that remains is to return the snails to their place. That's all.

This article indicates a general algorithm for disassembling and assembling a turbine. Of course, depending on the type of the latter, this algorithm will be partially changed, but the general progress of work will be identical.

Well, if a serious breakdown is detected, then it is better to immediately replace the old turbine with a new one.

Turbocharger assembly

After completing the repair, all that remains is to assemble the unit and put it in place. Don't forget to check the tightness of the retaining rings when installing them on the cartridge. If they do not sit in the nests, the structure will crumble during operation.

Liners, bushings and shaft oil scraper rings are lubricated with oil before installation. This guarantees that there will be no scuffing during the first start-up.

1. The parts are assembled in the reverse order of their removal at the previous stage.
2. The impeller fastening nut is tightened with a force of 5 Nm, unless otherwise provided by the manufacturer's instructions.
3. The assembled device is placed on the engine and secured with screws or stoppers.

Assembly and balancing video:

Do-it-yourself turbocharger repair - causes of malfunctions and instructions

Just ten years ago, a car turbocharger moved from the category of a special chic inherent only in selected cars to the category of a necessary part for every car. It serves to increase engine power and helps reduce fuel consumption. These parameters are becoming increasingly popular when choosing a car. Therefore, today every driver needs to know the structure of a turbocharger and be able to understand what its malfunctions are in order to navigate and diagnose the breakdown of his car in time. In addition to the design of the turbocharger, you should also know the features of your car model; for this you should read the repair and operating instructions for your car, for example, the repair instructions for GAZ 3110 and Chevrolet Lanos.

Diagnostics of a removed turbine consists of 9 stages

• Checking the operation of the turbine actuator
• Checking the operation of the wastegate valve
• Checking the turbine for play
• We disassemble the turbocharger
• We inspect the condition of the impeller and rotor for damage
• We check the turbine shaft runout on a stand
• Checking the operation of the variable geometry mechanism if available
• Troubleshooting of internal components of turbocharger spare parts is carried out
• Check the turbocharger for oil leaks if necessary

Turbocharger device.

• Turbine with impeller.
• Air centrifugal pump.
• Compressor.
• A rigid axis that connects them.
• Bearings, rings, valves, seals and other small parts.

These malfunctions do not always relate to problems with the turbocharger; sometimes it can be something else, for example, you need to repair the muffler yourself.

Exhaust gases escape from the engine and enter the turbine impeller. It converts their energy from kinetic to mechanical, and the pump through the air filter supplies fresh air to the compressor, which compresses it and sends it to the engine. This entire process helps increase engine power by 20-50%, increasing efficiency and fuel burning rate.

What are the types of turbocharger malfunctions and how to recognize them?

1. Your engine suddenly seems to lose power.
2. Black or dark blue smoke comes out of the exhaust pipe.
3. Oil consumption has increased.
4. The sound of the engine and turbocharger has changed.

All this indicates that it’s time to make sure you have a turbocharger repair kit and check the serviceability of not only the turbocharger, but also, first of all, the car’s engine and all its attachments. Do not neglect this advice, because a well-maintained and properly functioning engine ensures trouble-free operation of the turbocharger for many years.

Is it possible to repair a turbocharger with your own hands? What equipment and skills are needed for this?

Let us say right away that not a single specialist will advise you to disassemble and repair the turbocharger yourself. The reasons for this are compelling and it will suffice to name at least one of them. For example, the slightest grain of sand entering a unit can damage it. But there is another opinion - if someone does it, then I can do it too! If you decide to disassemble and repair the turbocharger yourself, prepare a minimum turbocharger repair kit: liners of several sizes, a full set of all kinds of seals, rings, washers, screws, screws and spare liners. Be extremely careful and remember that taking something apart is easier than putting it back together. If possible, mark all the fastening points of the parts and their position relative to each other.

So, we begin repairing turbochargers in our own workshop.

1. We remove the turbine and free it from all screws. We also unscrew the screws securing the snails.
2. We check both impellers: turbine and compressor. They cannot be repaired, but will have to be replaced in case of malfunction.
3. You can try to grind the shaft on which the compressor and turbine are mounted. Then you will need to replace the bearings with others that fit in size.
4. To remove the compressor wheel, you will need pliers with sliding lips. And you must take into account that the compressor shaft has a left-hand thread!
5. It is very difficult to check whether the shaft play is acceptable in a regular workshop. But here we take a risk, hoping for luck and the opportunity to go to the workshop later.
6. Using a universal puller, we try to remove the compressor wheel from the shaft.
7. Shaft bushings are very often the cause of backlash.
8. We clean and rinse all parts with special products. During assembly, some components and parts are forcibly lubricated with oil, which is used when operating the car. The list of such details varies in each specific case.
9. Don't forget to congratulate yourself after you managed to assemble the turbocharger! And if he still works, it’s time for you to think about changing your profession. There is a good salary at the service station...

Before you decide to disassemble and reassemble a turbocharger in less than ideal conditions, without having experience in such work, carefully weigh the pros and cons again.

A professional workshop has the opportunity to diagnose all components and parts of any turbocharger at all stages of repair, including before and after disassembly and assembly. And conditions of cleanliness have been created there, which cannot be achieved in a home workshop even if one wants to. After all, you don’t have a special unit in your garage - a high-pressure washing machine, for example? What about the balancing stand? As you understand, we strongly do not recommend repairing the turbocharger yourself and insist on it!

We check both impellers: turbine and compressor. They cannot be repaired, but will have to be replaced in case of malfunction. We advise on

DIY repair

It is important to purchase a repair kit, after which you should disassemble the turbine. Since there is a risk that the snail may become stuck due to high temperature, it is necessary to apply maximum force. You need to carefully unscrew the turbine crosswise, as in the case of removing a wheel rim. After that, you should check the shaft play. There should be no transverse play, and with longitudinal play there should not be an excess of 1 mm. To remove the compressor ring, you need to use pliers. In this case, it is necessary to clamp the mandrel of the other end of the shaft.

After removing the compressor wheel, be sure to mark the location of the wheels and nuts. You also need to remove the shaft bushings and the liner that holds the retaining ring on the compressor side. It is important to thoroughly clean the shaft and liner from dirt. You need to remove the sealing ring from the shaft, and then replace all the liners, rings and washers with parts from the purchased repair kit.

Be sure to lubricate the liners with oil. Then you need to insert the inner retaining ring into the liner and make sure that all the grooves are in place. After this, you need to insert the liners and lubricate the bushings. The next step is to put on the oil scraper ring, install the plate and tighten the bolts. It is important to securely fix the dirt protection plate using locking rings. First, the oil scraper ring is inserted, and then the shaft. After that, you need to secure them with a nut.

First, you should find the cause of the breakdown and choose the appropriate way to fix the problem. It is recommended to repair a diesel turbine with your own hands exactly when necessary. Especially if there are no reasons for the motor failure. After all, it may be that the cause of the malfunction is completely different, but the effort and time are wasted.

Please note: The main factors that determine the success of the repair are the quality of the components and the quality of the repair itself. That is, you need good spare parts, ideally original ones, and the craftsmen must be highly qualified. Remember that if you check the engine in a timely manner and repair it, its life will be extended, and you will avoid serious troubles and money.

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How to remove the turbine?

To change the turbine yourself, you must first dismantle it. The removal procedure can be performed in a garage.

What will you need?

Before removing the turbine, prepare the following for the task:

• a set of screwdrivers - with a Phillips and a flat tip, preferably of different lengths;
• set of wrenches;
• ratchet wrenches 1/2 and 1/4, preferably with extensions;
• WD-40 liquid.

Algorithm of actions

If the car is more than five years old, it is recommended to treat all fastening nuts and bolts with WD-40 the day before the dismantling procedure.

We are talking about the elements of fastening the turbine to the manifold. This will make the dismantling procedure easier.

The removal process is performed as follows:

1. The machine's power supply is turned off. To do this, the terminals are disconnected from the battery in the engine compartment.
2. To carry out work, it is necessary to ensure free access to the unit. The turbine is located between two manifolds - exhaust and intake. If the car is rear-wheel drive, then the unit is installed to the right of the engine. If the car is equipped with front-wheel drive, then you need to look for the turbine to the left of the power unit.
3. All components and assemblies that may interfere with the removal of the turbine are dismantled. Here you need to focus on the design features of the internal combustion engine. The generator unit, battery, or windshield washer system reservoir may interfere with dismantling. The fasteners are removed and these elements are dismantled.
4. The turbines of modern cars are equipped with many controllers. We are talking about a gas temperature control sensor, a pressure controller, the health of the unit, etc. Before dismantling the unit, these devices must be disconnected from the on-board network by removing the connectors. If this is not done, the wiring may be damaged.
5. The cooling system pipes are disconnected, as well as the lines of the turbine cartridge lubrication system. When disconnecting, it is recommended to mark the hoses so as not to mix them up during further installation. It is necessary to dismantle or disconnect the line for draining the engine fluid from the cavity of the cartridge into the crankcase of the power unit.
6. The next step will be dismantling the turbocompressor unit. It can be fixed on the uppipe, downpipe or power unit block. First, the section of the line that goes to the exhaust pipe is dismantled. When performing the task, you must not lose the sealing elements and nuts.
7. Then the upper line is disconnected, it is dismantled a little easier. Through this hose, compressed air flow is supplied to the power unit, so the temperatures in this line are lower. As a result, the condition of bolted joints is better.
8. If the turbine is fixed to the block, then this fastening must also be unscrewed. After this, the unit is disconnected from the collector unit and dismantled.

The DIY repair channel Audi Q7, A6, VW talked about dismantling the turbine using the example of Audi and Volkswagen cars.

What problems do car owners face when repairing turbines?

Violation of deadlines. The unit can lie in the workshop for a long time because the company does not have established technological processes or does not have a spare parts warehouse. As a result, your vehicle is idle.

Poor quality services. Craftsmen do not comply with the requirements of technical regulations and use spare parts of unknown origin. The production site has outdated technologies, the quality of operations is not controlled, and cleanliness and order are not maintained.

Unreasonable price. 80% of car repair shops are direct or secondary intermediaries. As a result, the markup is 200-300% and the order delivery time is delayed until the node goes through the entire chain of third parties.

No guarantees. If the turbo repair of turbines is mediated, the warranty card is given for no more than a year or not at all. Therefore, when problems arise, car owners do not know where to turn.

Rude attitude towards customers. Many car repair shops act as if they are doing you a favor and fulfilling your order for free.

Inaccessibility. In order to rent space inexpensively, companies set up car repair shops in villages or industrial zones in a confusing location. To find them, you have to circle around, ask passers-by, or call the base several times.

We know about these problems and have done everything to make it convenient for you to work with us, and the turbine after repair works just like a new one!

Disassembly

Do-it-yourself repair of a diesel engine turbine in a car or truck begins with its dismantling. To do this you need to perform the following operations:

• unscrew the bolts or remove the stoppers securing the housings of the compressor and turbine unit;
• if the knot is stuck, it needs to be carefully “awakened” by tapping with a mallet;
• remove the snail.

First you need to check the cartridge bearings: longitudinal play is unacceptable, transverse play is only very small. AND

The compressor retaining ring is removed using pliers with sliding jaws. The reverse side of the shaft is clamped with a figured straightener.

When disassembling, do not forget about the left-hand thread on the shaft.

Video on disassembling a diesel turbine:

How much does a turbine cost?

Turbine service life - general recommendations

To ensure proper operation of the turbocharger, it is recommended that the vehicle be thoroughly maintained regularly. Do you want your turbine to serve you for a long time? Just stick to a simple list of recommendations.

• Perform regular maintenance;
• Change your engine oil regularly;
• Fill only with high-quality oil;
• Change oil and air filters regularly;
• Do not use untested engine additives;
• Follow the vehicle manufacturer's recommendations.

For high-quality repairs of turbochargers, contact trusted specialists. For a long time, our company has been engaged in the repair and complete restoration of turbochargers. We have gained considerable experience in the field of turbine repair. For us, the market coverage of turbine repair services is not limited to local, local activities. Many foreign partners prefer to trust the repair of turbochargers to our specialists. Our success in the turbine repair industry is primarily due to the high quality of our services. High-quality turbine repair is the beginning and continuation of our professional and beloved business. Without a doubt, we are always ready to provide assistance in the repair of turbochargers, both to large partners and to ordinary repairmen who repair turbochargers.

When should you contact us?

The following symptoms of malfunctions are grounds for contacting turbo service:

• Increased consumption of working fluid;
• Oil leakage from the turbocharger or connecting pipes;
• Increased fuel consumption;
• Loss of motor power;
• Deterioration in acceleration dynamics;
• Extraneous noise, grinding or whistling when the engine is running;
• Heavy exhaust smoke (black, white or blue smoke).

If you notice the first signs, contact a service center for engine diagnostics or maintenance. If the motor malfunction is related to the poor condition of the turbine, remove and bring the device to our base for a thorough inspection and subsequent repair. We will diagnose it through external inspection, using tools and on a stand using licensed computer programs.

Repairs and diagnostics of turbines are carried out by mechanics with at least 12 years of experience in this field.

Typical errors

Before you repair a modern diesel turbine with your own hands, you need to remember a common mistake made by beginners. There are gaps between the body, bushing and shaft of the cartridge that are filled with oil during operation. They allow you to compensate for the damper effect.

Inexperienced mechanics regard this as excessive play and install bushings of non-standard sizes, which are mounted “in tension”. As a result, the rotation of the rotor becomes difficult, and the bushing wears out intensively due to the damping effect and lack of lubrication. This often causes shaft deformation.

Also, we must not forget about balancing, which is performed on a special stand. It is possible to balance a part yourself, but it requires skill and attention. Repair and assembly errors lead to irreversible damage to an expensive unit. Therefore, in case of any difficulty, it is better to contact specialists.

Complete or standard turbocharger repair

The cost of repairing a turbine is determined by the complexity of the breakdown and the cost of parts replaced during repairs. The approximate cost of repairs is determined after diagnosing the turbocharger. Turbocharger repair is divided into two types, more precisely, into two repair categories.

Standard turbocharger repair

The first category is “standard turbocharger repair.” Standard turbine repairs are performed when bushings, gaskets, rings and other small parts are worn out. The repair uses a new repair kit (repair kit) for the turbocharger, and replaces all parts from a repair kit suitable for the given turbine. The shaft and impeller, while in good condition, cannot be replaced.

Work progress, actions performed during standard turbine repairs:

• The turbocharger housing is dismantled;
• All turbine mechanisms are disassembled;
• The turbocharger parts are placed in a washing device and washed with special chemicals. In the cleaning chamber of the cleaning device, dirt in the form of soot, rust, soot, coke, burnt oil and other contaminants that are a product of the internal combustion engine is removed;
• The surfaces of the turbine housing in special equipment are subjected to cold abrasive treatment using abrasive powder;
• The housing and parts of the turbocharger are washed again in a chemical solution;
• Using special equipment, the turbine rotor (shaft with impeller) is balanced;
• The core (turbine cartridge) of the turbocharger is assembled, into which high-quality parts of the new repair kit (bushings, rings, etc.) are mounted;
• The turbine cartridge is balanced using special balancing equipment;
• The turbocharger is completely assembled;
• The progress of the turbine repair is completed by a final check of its performance, final tests and performance measurements are performed.

Complete turbocharger repair

The second repair category is “full turbocharger repair.” A complete turbine repair is performed when the rotor (shaft and/or impeller) is severely worn. The process for a complete turbocharger repair is similar to a standard repair, with the exception of the need to replace a faulty rotor, worn shaft and/or impeller. When performing a complete turbine repair, it is possible to replace the entire cartridge (turbocharger core) entirely or replace its individual parts.

Actions, progress of work in case of complete repair of a turbocharger:

• The turbocharger housing is disassembled;
• All turbine mechanisms are dismantled;
• In special equipment, parts are cleaned using chemicals. Removes carbon deposits, rust, soot, coke and other contaminants typical of a turbocharger;
• Using cold abrasive treatment, the surface of the turbine housing is cleaned;
• In the cleaning chamber, turbocharger parts are re-cleaned using chemicals;
• The cartridge (turbine core) of the turbocharger is assembled, consisting of a new, pre-balanced rotor (shaft with impeller), bearing housing, bushings, rings and other parts. As with the standard repair, the reassembly also uses a new turbocharger repair kit;
• The assembled cartridge is placed in special balancing equipment, where it is balanced with the parameters specified for the current turbine;
• The turbocharger is completely assembled;
• The complete repair work is completed by a general check of the turbine’s operability and the completion of all tests for the suitability of the turbocharger for operation.

Turbocharging defects and causes of their occurrence

Malfunctions of diesel and gasoline engine turbines are no different from each other. Below are some of them:

• Wear of the shaft bearing journals and sliding bearings. Reasons: low pressure, poor quality or severe contamination of the oil. A sign of this malfunction is the noisy operation of the turbine at any speed.
• Mechanical damage to the impellers. Occurs when there is a large uneven wear between the shaft and the bearings, leading to the impellers beating against the housing. Or when foreign objects get on the impeller blades.
• Clogging of bearing lubrication channels with burnt oil. This is possible when turning off the diesel engine immediately after stopping the car. Because if, after stopping the car, you do not allow the engine to idle for several minutes, overheating of the bearing housing is inevitable. And in the case when the turbine is liquid cooled - when the thermal conductivity of the channels of this system decreases due to the deposition of scale or antifreeze sealant on their surface.
• Oil entering the engine intake manifold from the turbocharger. The reason is increased gaps between the surfaces of the shaft journals and the bearings, together with a clogged oil drain line. This makes itself known by the appearance of blue smoke at high engine speeds. As the crankshaft speed decreases, the exhaust becomes almost colorless.
• Actuator malfunction. Most often this is a jamming of the bypass valve in one of the extreme positions. A sign is insufficient compressor boost or exceeding the permissible impeller speeds.
• Leaks in the joint between the compressor scroll and the intake manifold. The reason may be a violation of the geometry of the turbocharger housing or the gasket becoming unusable. This malfunction reveals itself by the whistling sound of compressed air escaping through the defect.

Removing the turbocharger

1. Cool the engine and drain the antifreeze.
2. Disconnect the oil lines and cooling pipes from the assembly housing.
3. Unscrew the volute flange fasteners. To avoid damaging the edges of bolts or nuts, use only box and socket wrenches.
4. Disconnecting the compressor volute flange from the intake manifold is usually not difficult. The turbine scroll flange usually sticks tightly to the exhaust system. To separate this joint, you should use WD-40, and if this does not help, then a wooden mallet.

What is a turbine cartridge

An engine turbocharger cartridge is a unit consisting of a bearing housing, liners and a shaft with impellers installed in them. Available for sale, it does not require balancing the shaft with impellers or other preparatory operations and, after removing the preservative grease, is completely ready for installation.

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