Message Thread was - "Turbo - oil in air cleaner pipe"
I've now removed the turbo and have the following observations in case this helps diagnostics and to invite comments:
1. A fair amount of water came out when the water pipes flange was undone. This flange was not mentioned in the RM025E manual.
2. No oil came out when the oil pipes flange was undone - it was definitely wet though.
3. There doesn't appear to be a removable compressor elbow with relief valve as mentioned in the RM025E manual.
4. The large metal pipe across the top of the back of the engine was filled up in one area by approx. 5mm depth of grimy soot at the engine inlet manifold end.
5. The exhaust inlet, outlet of the turbine and the propellers are evenly covered in a fine layer of soot.
6. The axial play of the propeller shaft is large, around 2mm and I can see shiny metal on the casing in the region of the propeller fins (rubbing on sides = screeching?)
7. On the left hand side of the engine there is a brown staining all over (previous coolant problem?)
8. Most, if not all, flanges are kind of pitted/ruptured and stained brown (is that a problem - cleaning, rubbing down required?)
9. Should I replace all gaskets or is it easy to inspect gaskets to see if still usable?

I am assuming the following actions are needed:
1. Find replacement Turbo. I will look on ACE Answers for guidance but if anyone wants to guide me here that would be appreciated e.g. part number & alternatives, what vehicles (at breakers), recommended sources and quality/quick checks.
2. Replace all gaskets. Again I will look on ACE Answers but any guidance here would be appreciated.
3. Clean up flanges. Recommended methods.
4. A couple of studs came out of one of the flanges on the Turbo. One the studs on the exhaust manifold for the EGR pipe one stud thread looks damaged and two different nuts are used. Can I assume no special care is needed and a decent car shop would be able to offer guidance?
5. Clean large metal pipe of significant grimy soot deposits (and at manifold). Should I also try to remove the fine layer of soot including in the manifolds (I'm hoping the answer is no!).
6. Any other useful checks or actions?
- (#8020) Peter Dawson, 12 Apr 03

Another thing the wastegate stuck open the first time I pumped it and released then it behaved alright after that

- (#8021) Peter Dawson, 12 Apr 03

Good work, Peter. Now while there's a fair bit of play in your turbo, the sticky wastegate sounds like an explanation for your power loss issue. Is there any oily gunge in the exhaust housing? how oily is the compressor housing?

If you can do without the vehicle for a period, get your own turbo rebuilt, unless funds are extremely tight. If you go s/h, dont touch it, just fit and pray- seals disturbed could be hassle.

re your observations, the repair manual refers to a Camry TD in the turbo section. Same but different... (some earlier turbos didn't have water cooling for example)

Best to replace any gaskets disturbed, but use you discretion...

- (#8022) david miller, 12 Apr 03

Inexhaust Manifold (fitted between turbo & cylinder block) and also at the exhaust inlet to the turbo there is an even covering of dry soot. Turbine elbow is the same. Compressor housing (integral to turbo - not removable & with no relief valve)(receives wrapped pipe from the large metal pipe over back of engine) - this is definitely oily as is the pipe attached to it but as to 'how oily' I don't know what to expect. You may recall my initial observations in the earlier thread on how oily the pipes were. I mentioned major deposits at the cylinder block inlet manifold flange to the large metal pipe across the back of the engine. Is that a concern?

Re
turbo rebuild - do you mean do it myself - that would be interesting - where do I get the parts - you mentioned elsewhere the turbo is difficult to rebuild? Or do you mean elsewhere - what kind of place should I approach and can you recommend one - How long would a rebuild take - what about rebuilt part-exchange rather than a straight second-hand or own rebuild?

What about the flanges what sort of attention do they need?
- (#8023) Peter Dawson, 13 Apr 03

don't worry about the flanges too much. just put a straight edge on them to check flatness, and dress lightly if needed.

Rebuild= exchange. It's just possible to rebuild your own turbo (I've done it...) but you need steady hands, some odd tools, and a £150 overhaul kit. Best to double that and have it done by the pros...

Oil and soot buildup is normal, 5mm in the inlet, not surprising.

- (#8024) david miller, 13 Apr 03

Peter. If you do go for the "professional rebuild" route, you will probably find a local turbo re-build Company listed in, say, Yellow Pages. One of the long standing and well recommended Companies is "Turbo Technics" of Northampton. They keep vast stocks of exchange turbos or, will re-build yours with, so I am told, a very quick turn round time. They have a website which will give you the information

- (#8025) John Davis, 13 Apr 03