If you’re experiencing issues with your T28 turbo and are considering a rebuild, this comprehensive tutorial will guide you through the process. While it does require some mechanical skills and specific tools, even those with moderate experience can successfully complete this project. Rebuilding your turbo can be a cost-effective way to restore performance and extend its lifespan. Just make sure to follow these instructions carefully.
Disclaimer: Rebuilding your turbo involves intricate mechanical work. If you’re not confident in your abilities, it’s advisable to seek assistance from an experienced individual.
Tools and Parts You’ll Need:
- Turbo rebuild kit: Ensure you choose a reputable brand for quality components.
- A sturdy snap-ring plier: For removing the main compressor housing snap ring.
- Small needle-nose snap-ring pliers: To handle smaller snap rings, circlips, and piston rings.
- 13mm spanner: Required for loosening compressor bolts and exhaust housing.
- 14mm spanner and/or Vice Grips: Used to secure the exhaust turbine shaft while removing the front compressor turbine nut.
- Torx screwdriver: A small-sized one is needed to remove the thrust bearing’s Torx screws.
- Rubber hammer, pick tools, and miscellaneous tools: Essential for disassembling and reassembling various components.
- Torque wrench (may not be necessary, as explained later).
- Preparation: Before starting, gather all the necessary tools and parts. This guide assumes that you’re disassembling the turbo while the braided flexi-oil line is still attached, so you won’t need to replace copper rings.
- Organize Your Work: As you disassemble the turbo, keep parts in the order they were removed. This will make reassembly much easier.
Step-by-Step Rebuilding Guide:
Step 1: Separating the Turbo
- Begin by loosening the four exhaust housing bolts that secure it against the center cartridge. Ensure you mark the compressor housing’s position relative to the exhaust housing to retain the correct alignment.
Step 2: Undoing the Compressor Housing
- Use a big snap-ring plier to remove the snap ring that holds the compressor housing. If it’s stubborn, carefully tap it off with a rubber hammer.
Step 3: Marking the Position
- Before removing the nut on the compressor side, mark the position of the compressor wheel relative to the shaft. Precise marking is crucial for reassembly.
Step 4: Removing the Turbine Wheels and Shaft
- Remove the nut on the compressor side (remember, it’s a left-hand thread). Use a 14mm spanner to hold the exhaust turbine shaft while undoing the nut.
- After removing the nut, try to gently lift off the compressor wheel. You may need to use a gear puller to push the shaft down through the wheel, creating space to remove it.
Step 5: Getting Closer to the Core
- Remove the snap ring behind the compressor wheel and slide off the plate beneath it. Replace the O-ring before reinstallation.
Step 6: Disassembling the Exhaust Side
- Begin working on the exhaust side by carefully removing the double-layered snap ring. Beneath it, you’ll find a washer.
- Slide out the turbo’s bearings using suitable tools.
Step 7: Removing the Top Plate
- If the top plate doesn’t come off easily, you may need to resort to unconventional methods. Carefully use a chisel to apply pressure to the thrust bearing, shocking the top plate loose.
Step 8: Replacing the Inlet-Side Components
- Replace the O-ring and bearings on the inlet side. Ensure proper alignment and use thread locker on the Torx screws that hold the thrust bearing.
- Install the new piston ring, ensuring it snaps into place, and replace the top plate with a new snap ring.
Step 9: Replacing the Exhaust Side Components
- Remove the circlip below the bearing, if necessary.
- Replace the bearing and washer in the order they were removed.
- Carefully install the piston ring behind the turbine wheel.
- Carefully reassemble the turbo components in the correct order, following the markings made earlier.
- Be extremely cautious when reinstalling the compressor housing, ensuring that the large snap ring sits securely inside it.
- Torque the nut on the compressor side to 20Nm or tighten it by feel, depending on your comfort level.
By following these step-by-step instructions, you can successfully rebuild your T28 turbo. Remember that the shaft may take some time to “run in” with the new bearings during your first boosted run. Make sure to double-check all connections and enjoy your turbo’s renewed performance. Good luck with your project!
You can find the source link for the original tutorial on how to rebuild your T28 turbo by Vova at the following location:
Please visit this link to view the original tutorial and give credit to Vova for their valuable contribution.