[KB] Rebuild Your Turbo

[niz406]

Peugeot 406 Turbo Rebuild by Niz406

Parts Needed:

Garrett Service Kit
Oil return hose gasket
TetroClean - Engine degreaser
Tooth Brush
Wire Brush for a drill
Wire-wool
Tub for cleaning parts
Tub - to retain old parts
Tip-Ex
Silver VHT Spray Paint

Tools Needed:

10mm combination spanner
13mm combination spanner
17mm combination spanner
19mm combination spanner
T15 torx drive
Needle nose circlip pliars
Large circlip pliars
T-Bar with 5/16 12 sided socket
2 legged Puller
Bench Vice
Center Punch
small Hammer
Mallet

Preperation:

Before begining it is important to ensure that you have a clean work area with plenty of space... I started by covering the work bench with a plastic sheet this also helps keep any spillages from staining/damaging the worktop. Make sure you have a fresh supply of clean cloths... any bits free will do, I used 100% cotton sheet.. if you need to nip to dunelm you can get one for circa £4!

Ancillery removal:

1) Remove retaining clip from Actuator Rod.
2) undo the 10mm Actuator mounting bolts and place the actuator to one side.
3) Next remove both 17mm inlets from the core, oil feed and water return - save the brass washers.

Exhaust and Compressor Housing Removal:

To ensure correct refitting you need to mark the location of the comp cover and exhaust housing in relation to the core. The simplest method to do this is to use a center punch and hammer. Place the turbo in your vice now the best part to punch first is the core on the oil return side, as you are looking at the turbo you should have the coolant return union facing you, simply punch the core below this.

Next using a straight edge mark the exhaust housing in the same location. Then finally the same with the comp cover, these will be the identifiers used for replacing both housings to the core, if you do not do this you may have problems conneting your turbo's hoses and exhaust back together. Now onto the removal process:

1) Slacken the 13mm exhaust housing bolts working diagonally until they are touching the core, here you have two options (I did the first one, as it was quicker)
1.1) Tap the housing with a mallet to break the seal and seperate the items
1.2) Continue to undo a bit at a time using the core to force the housing away from the core.

2) Remove the bolts and slide the exhaust housing away from the core, avoid fouling the turbine wheel.

3) Turn the turbo over and place the compressor cover inlet in your vice and tighten a little to stop it falling over.
4) Using the large circlip pliars remove the compressor cover circlip - use a rag to place over the clip on the opposite side to your pliars to prevent your hand from getting caught out!
5) Retract the core from the housing, remembering not to foul the compressor wheel.

Shaft Removal:

It is now important to mark the shaft, compressor wheel and retaining nut in relation to each other, doing this will lead to not requiring a rebalance... When removing the retaining nut, mark the last position of it in relation to the shaft with another marker, this will help when rebuilding... if you skip this step you will need to have the unit balanced before using to avoid damage to the turbo and potentially the engine:

1) Using your tip-ex mark the inside of the shaft at the compressor end, draw the line over the retaining nut and onto the centre of the compressor wheel, let this dry if you have not marked it clearly enough make a second pass.
2) Place the turbine wheel lug in your vice and make sure you tighten it well to avoid slipping and damaging the lug and/or the wheel as this will result in a rebalance being required.
3) Using your T-Bar and 5/16th socket remove the compressor wheel retaining bolt. *IMPORTANT* this bolt has a left hand thread so tighten it to remove it (clockwise).
4) You may need to use a two legged puller to remove the wheel from the shaft. If so place the core in the vice and use the puller connected to the core.
5) When removing the shaft from the turbo the heat shield / cover will come with it from the turbine side, retain this!
6) Place the shaft to one side, making sure there is no potential for it to get damaged.


Core dismantle:

You now need to remove the thrust bearing, thrust plate, bearing circlips and bearings from the core all of these parts will be replaced by the new items from the rebuild kit.

From the compressor side:

1) Remove the Circlip holding the seal plate to the core, retain this for later use.
2) Recover the large O' ring below the seal plate.
3) Using a very fine flat head screw driver, prise the seal plate up to break the seal and remove.

Looking into the core you will see your thrust bearing, thrust plate and three T15 torx screws holding the plate in place as depicted below:

4) Slacken and remove the 3 torx screws.
5) Grasp the thrust bearing and lift out of the core - this will remove the thrust plate too.
6) Turn the core over and one bearing will fall out of the core - below the bearing is a retaining circlip.
7) Using the needle nose circlip pliars remove the small circlip, taking care not to scratch / damage any part of the bearing journal.

From the turbine side:

8 ) Remove the small circlip retaining the bearing in the journal, taking precations as previous.
9) Turn the core over to allow the bearing to slide out.
10) Finally remove the last of the circlips - this one is tricky and I would advise again that you take great care not to scratch the journal.

Inspecting, Cleaning / Correcting:

This is the vital stage in the rebuild process, you have to throughly clean all components and ensure that the core is free from water, oil, or any other chemical or foreign objects.

Inspection:

1 SHAFT ) Check the Shaft for any signs of scoring, discoloration or damage, if there is any you will need to lap the shaft to remove imperfections (unless it is quite severe then you will need to replace and rebalance).
2 COMPRESSOR WHEEL ) Look for any signs of burring where the wheel may have come into contact with the cover or a foriegn object - This will result in a replacement being needed and yes rebalancing.
3 CORE ) Check the bearing Journals for any signs of scoring, discoloration or damage, (if you have internal micrometer / telescopic this will help check the condition of the bores) if there is any you will require some machining to remove imperfections ( This should not be attempted at home )
4 COMPRESSOR COVER ) Inspect the inside for any impact damage from the wheel or any cracks. You will need to lap this if there are any major scores or have it machined.

Cleaning / Correcting:

SHAFT - Cleaning

1) Soak the turbine end of the shaft in TetroClean and allow to soak into the carbon deposist.
2) Remove the piston seal from the end of the shaft under the wheel
3) Using a fine wire brush or similar clean out the two channels from under the wheel on the shaft, piston seal channel and the spare.
4) Repeat steps 2 & 3 until carbon has been removed.
5) Rinse the wheel end of the shaft in water to remove the degreaser.
6) Dry completely


SHAFT - Correcting

1) Place the shaft, wheel end into a drill mounted on your vice or on a lathe if available.
2) Spin the shaft up and lap with wire-wool ensuring light even strokes.
3) stop and inspect.
4) Repeat 2 & 3 until no imperfection remains.
5) Remove Shaft - use TetroClean on a rag to wipe away any metallic-dust.
6) Rinse under water and then dry completely.
7) Replace piston seal - taking care not to scratch the shaft surface.
8 ) Place shaft in a clean tub or plastic bag.

COMPRESSOR WHEEL - If you are simply servicing then you do not need to clean the compressor wheel, you want to avoid removing the tip-ex from the marked components. If you notice oil on the wheel then simply wipe away with a cloth soaked in some Tetroclean and then wipe with a damp cloth.

CORE - If the core is damaged or there are any scores in the bearing journals you will require a donor, a new core or some machining work, this aspect of the servicing / rebuild process is beyond this article.

Cleaning:

1) Place core in a suitable container and fill with Tetroclean leave to soak for a while... hours not minutes. ( Refreshing the degreaser where nessecary )
2) Once soaking has broken down the oil and part of the carbon you now need to use a toothbrush to brush the journals and oil ways clean from any fluids / solids left.
3) Rinse the core using a jet wash where available or under a hose!
4) On the turine side of the core you will need to clean the carbon off with a wire brush attachment on a drill, ensure that the mating faces of the wheel and the core are prefectly clean and free from carbon.
5) Once all of the carbon is off repeat steps 1 - 3 again.
6) Dry the core and place somewhere safe.

COMPRESSOR COVER - Cleaning:

1) Place cover into a suitable tub and soak in Tetroclean, use a stiff brush to remove built up dirt / grease from the cover.
2) Again jet wash or rinse to remove chemicals
3) Repeat steps 1 & 2 if needed.
4) Dry completely.
5) MAsk off the inlet and backing
6) Spray with silver VHT Paint

You can also Clean and Paint the Actuator as well if you want to make it look like a new unit, these are the steps I took!

1) Wire brush the entire actuator and mounting bracket back to its base - using either a hand brush or electric drill.
2) Mask off The Rod, Rod apature, Hose connection, and bracket
3) Prime the actuator and allow to dry, typically 20 minutes for the size.
4) Spray top coat, I used a black and the finish wasn't too bad! Allow to dry for a few hours or over night.
5) Remove masking.


Rebuilding: Ensure that your service kit has all of the required parts before beginning, seperate these ready on the worktop for easy access.

The fun part - Staring with the core - Tubine Side

1) Using your needle nose circlip pliers insert the first circlip in the recess approx 12-15mm down the bore, ensuring that the circlip is secure and that there is no movement.
2) Dip one of the tall bearings into some engine oil and then place into the core, this will be heald in place by the first circlip.
2) Using your needle nose circlip pliers insert the second circlip to retain the bearing.
3) Turn the core over to the compressor side
4) Insert the final retaining circlip in the recess approx 12-15mm down the bore ensure it is in place and secure.
5) Dip second bearing in oil and then place on top of circlip in the bore - this bearing is held in place by the thrust bearing / plate components.

270 Thrust Bearing kit - 2 Piece | 1 Thrust bearing / 1 Thrust Bearing Plate
6) Fit the Thrust bearing collar, be sure not to snap as this is a britle ring.
7) Slide the underside of the thrust bearing (non-collar side) into the thrust plate.
8 ) Lower the bearing and plate into the core, VITAL: Make sure the oil ways are face down and then line up the torx screw holes. Oil way is a hole in the thrust plate that lubricates the thrust bearing assembly, failure to put this on the right way will result in an almost instant death of the turbocharger.
9) Tighten the torx screws hand tight with a small T-Bar and Bit set or Small Ratchet. Do not over tighten!!

360 Thurst Bearing Kit - 3 Piece | 2 Piece Thrust Bearing / 1 thrust bearing plate.
6) Place the small thrust insert tube on top of the bearing in the core.
7) Lower the thrust bearing plate into position, make sure the tube slides through the centre and that the oil way is face down on the thrust bearing plate.
8 ) Secure the plate with the torx screws - hand tight!
9 Fit the thrust bearing collar and sit the second half of the thrust bearing on top of the plate, some of these have a second locator tube which slides into the center of the plate and within the small thrust insert tube.

In both cases:

10) Fit the seal to the new thrust plate / compressor backing plate.
11) Place this over the thrust bearing, ensuring that it slides down to cover the collar.
12) Secure with the large retaining circlip, again using a cloth to hold one side of the clip in place to protect your.

Refitting the shaft - this is simple!

13) Turn the core over to the turbine side, cover with a cloth so nothing can get in the inlets or outlets, place in a vice.
14) Dip your finger in some oil and run this over the bearing contact areas of the shaft (two larger diameter sections of the shaft)
15) Replace the turbine backing / seal plate
16) Slowly Lower the shaft through the plate and into the core - avoid scraping at all costs.
17) With the shaft resting on the plate - use both thumbs to apply downward pressure to the turbine lug, wiggle a little - once you feel/hear a click, the shaft is in place - Well done!.

Refitting the compressor wheel:

18 ) Turn the core over to the compressor side, cover with a cloth so nothing can get in the inlets or outlets, place in a vice and secure in place using the turbine lug - Make sure the vice is tight to avoid damage.
19) Place the compressor wheel over the shaft - make sure you line up the markers so that it will be balanced.
20) Add the retaining nut and tighten until the markers all line up - shaft/wheel/nut if this is not the case you will need to remove and try again. This nut is hand tightend using a T-Bar to avoid bending of the shaft, and you must ensure the markers line up.

Core Rebuild Complete - Refitting the compressor and turbine covers is a reversal of the removal procedure at the top of this article. Once you have refitted the covers, make sure to refit the inlet and outlet unions and again hand tighten.

Congratulations you have just rebuilt your own turbo and saved yourself around £400 so why not go spend that money on something new for the 406, or if you really feel like making someones day... the misses?! LOL ! !

If you have any questions about the rebuild process, please feel free to send me a PM and i'll respond as soon as possible.

[niz406]

There will be pictures to follow once Nick get's round do it !