TD04 Turbo rebuild

[FredVenne]

Alright,

So I've been looking and some places they name the engine 4D56T. But on my VIN plate, it says 4D56, no T. If I want to byuy the turbo repair kit that stipulates for engine 4D56T, should I go or should I not?

Fred

[Rattlenbang]

The "T" stands for turbo. It seems they made a few of those engines without the turbo, or just thought it was a cool prefix. But certainly if you are buying a turbo kit, you are buying it for a 4D56T, which is what we have in our vans.

[Tojo]

Hi Fred,

I just went through this, and all turned out well.

Glad to say that my turbo doesn't leak anymore, the process was relatively straight forward, and Rattlenbang's instructions make it much easier. The best thing for you to do is read the "turbo tag" which is a stamped number on the turbine housing. The number faces the front of the vehicle, but the downside is that you have to remove the drivers seat in order to read the tag.

Mine is a 1993 L300 4D56T, oil cooled and a flatback same as the OP: http://cgi.ebay.com/ws/eBayISAPI.dll?Vi ... 1114253451
and my turbo tag number was TD04 49177-01510 which matches the sellers description.

Unfortunately, I had to order a new cartridge. Not because I really needed it, because I could have recycled the old one, but because I whacked it too hard with the hammer trying to get it to press fit into the exhaust manifold and chipped it. Doh! Should have taken the extra 10 seconds and reached for the brass drift. Ah well, these things happen. Ended up getting a cartridge from Nerings, an ebay seller. Difficult to tell the quality but they claim to balance their turbos before sending them out. So far so good, and I notice the difference in performance. No leaks! http://www.ebay.co.uk/itm/Turbocharger- ... AQ:GB:1123

It's possible to do this job without removing the intake manifold, but I needed to remove the exhaust manifold because the bolts were all seized up.

1. Remove drivers seat
2. Remove and mark 2 hoses that go to the turbo
3. Remove air intake hose from the air filter can to the turbo
4. Remove waste gate actuator
5. Remove elbow from the turbo to the intake manifold (might as well blank the EGR while you're there if you haven't already)
6. Remove pyro if you have one
7. Remove sheet metal shrouds x 2
8. Remove oil line from back of head to the top of the turbo cartridge, careful not to lose the two thin brass washers
9. Remove all the nuts and washers that secure the exhaust manifold to the block
10. Remove exhaust pipe from exhaust manifold, careful the springs are under a lot of compression!
11. Remove exhaust support near rear heater to allow you to swing the exhaust out of the way
12. Undo the screw that secures the ground wire from the transmission to the underbody
13. With a helper, gently lower the turbo/manifold assembly down and out just behind the drivers side front wheel, very tight but it will go.
14. Then you are at STEP 1 of the original post with pictures!

Good luck.

[FredVenne]

The best thing for you to do is read the "turbo tag" which is a stamped number on the turbine housing. The number faces the front of the vehicle, but the downside is that you have to remove the drivers seat in order to read the tag.

Not necessarily... I used some paper towel to clean up the side, crawled underneath and used a mirror :-0

Thanks for the extra info, now I can order the part in confidence!

Fred

[FredVenne]

Alright! Got the parts and ready to do some micro surgery!!!

Now here is what the top part of my turbo looks like (Before I remove it all tomorrow).

Does this look like it is a leaky turbo to you? It seems like some new leaking oil come from those 2 small hoses. But I wonder how the rest of the older oil accumulate like that over time.

When I moved it earlier to the surgery room, I could here the high pitch sound that a turbo is suppose to make. So it still working. But I hope that with this kit it will stop leaking.

Fred

[Rattlenbang]

Was yours also a flatback?

[FredVenne]

Well, it was all the same numbers as Tojo's Turbo, so I took the chance and order a flatback kit.

I guess I'll find out tomorrow if I'm dumb or just lucky :)

[FredVenne]

Now here is my question.

I have not seen these 2 small snap ring anywhere... did I missed something? There in the kit, but not to be seen anywhere during the laborious process of removing all the turbo parts.

Any suggestions?

[Tojo]

KABOOM! Turbo is gonna explode dude.
....
...
..
.
kidding, I didn't use them either.

[FredVenne]

Hehehe...

I felt I was using an IKEA kit and bolts where left unused in the end.

Thanks!

[FredVenne]

Well sorry guys but I need your help again.

I have been putting back all the pieces together and I found out that the turbine is rubbing the inner-part that goes onto the manifold. Cannot figure out why beside the fact that I have removed all the gunk but really it does not make much sense. So I have been looking carefully and found out that it use to rub on the side (see photo with green line) and also found that crack (red arrow and line following the crack all the way down).

I guess right now I'm screwed and have to get either a new or refurbish part.

Any thoughts on this one?

[Rattlenbang]

I'm not sure that the housing needs replacing because of a crack, it doesn't move or anything. But if your turbine was rubbing on it, the turbine will be worn. I would try to figure out how or why it's rubbing first of all. If the housing is warped, the whole shebang needs replacing, but if not you can buy just the turbine. I can understand how worn bearings will allow the turbine to rub, but with new ones in there it shouldn't if everything is installed correctly.

[FredVenne]

Alright, I'll stop weeping and go back to work!

[FredVenne]

Alright, I'll stop weeping and go back to work!

Thanks a million by the way!

[FredVenne]

Well it is done! I have never did something like this before. Thanks to the help and patience from you guys. Now the real test is a good drive in the mountains up and down and passing cars at 120km/hr (kidding)!

Will also keep an eye from underneath and look for any leak around the turbo.

I love this forum, most of the time :)

Cheers and thanks again,

Fred, Kim and Yeti!