Changing turbo

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rutter123
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Changing turbo

Post by rutter123 » Sat Jun 20, 2015 8:59 pm

Several jobs to do on the t/d inc changing the turbo which has a lot of play on the shaft, current fitment being a kkk with a lucas fuel pump, any reason why i cant fit a garrett turbo as a direct replacement? Or is it the case that paired units are lucas/kkk or bosch/garrett? Which is the better turbo as rebuild kits are readily available.

Cambelt due, clutch release bearing whining, intermediate bearing noisy,, oil leak at back of engine i suspect is partly to do with the turbo, few repairs to return pipes and octopus needed, eng/box will be coming out.
90 BX Tzd turbo 294k SORN undergoing major surgery
90 BX Tzd turbo estate 46k awaiting surgery
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ken newbold
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Re: Changing turbo

Post by ken newbold » Sat Jun 20, 2015 10:23 pm

Sounds like a lorra lorra work. Pressume engine out first step?
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Re: Changing turbo

Post by rutter123 » Sun Jun 21, 2015 10:27 am

Hi ken, yes engine/box will be coming out, had quite a nasty engine oil leak coming from back of engine, i suspected the rocker cover so replaced the gasket but it appears to be lower down than that and dripping from the lower left side studs that fix the turbo to the block so could be the metal gasket, will also give me a good chance to change some return pipes that cross the subframe give it all a good steam clean, prob repair some unseen rust issues as well.
On the "to to" list cambelt water pump, clutch release bearing, clutch cable,poss clutch this one only done 50k, front strut rubber pipe work all the way back plus any others that look suspect, bottom rad hose, turbo either rebuild or replace, driveshaft intermediate bearing, exhaust both back boxes, o/s/r metal brake pipe, n/s/f wishbone bushes are oil contaminated, both bottom ball joints, fuel pipes, oils , filters etc and nsf brake caliper, time permitting replace the whole n/s sill, hopefully after that lot should be good for another 280,000, the mot has now expired so it makes sense to take it off the road and tackle all those long overdue jobs . Im sure there will be more bits along the way.
90 BX Tzd turbo 294k SORN undergoing major surgery
90 BX Tzd turbo estate 46k awaiting surgery
65 Peugeot Boxer Van the new workhorse
52 Toyota Rav4 180k Bulletproof Jap reliability

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ken newbold
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Re: Changing turbo

Post by ken newbold » Sun Jun 21, 2015 1:02 pm

wonder why these pug engines in Citroen's always seem to ooze oil out of every possible and often in-accessible orifice. Same engine in pugs seldom seem to suffer the same :-/ having said that, you can't really grumble at the mileage.
Some pics of the probs and progress might be interesting.
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rutter123
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Re: Changing turbo

Post by rutter123 » Sun Jun 21, 2015 1:44 pm

Agreed inaccessable areas do produce oil leaks, theres a lot of stuff at back of engine "in the way" of where i need to get, i managed to nip up all the bolts some time ago but the leak had appeared once more, rather than struggle to do it all in situ jobs like cambelt w pump and thrust bearing turbo gotta be easier out the car, hopefully should have it all done over next few weeks, will keep progress posted.
90 BX Tzd turbo 294k SORN undergoing major surgery
90 BX Tzd turbo estate 46k awaiting surgery
65 Peugeot Boxer Van the new workhorse
52 Toyota Rav4 180k Bulletproof Jap reliability

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themildbunch
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Re: Changing turbo

Post by themildbunch » Mon Jun 22, 2015 10:18 am

Once the engine and box is out it'll be a nice satisfying job!
The head gaskets can often leak oil around the back too although I found the cam seal on the HP pump end is a common leak point and neatly runs down, along the back of the head and onto the lower cam belt cover..

The T2 seems to be the preferred turbo around the various XUD forums - not sure if it's any longer lived but seems more popular and is easier to adjust the wastegate on compared to the KKK..
Rebuild kits are cheap but I think it needs to be balanced for a long lived rebuild, although I've heard others not doing this and they seem to run ok..
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rutter123
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Re: Changing turbo

Post by rutter123 » Mon Jun 22, 2015 2:08 pm

I think im going to stick with the kkk and rebuild it, i read that the kkk has the thicker 6mm spline as opposed to the 4mm spline on the t2, as for ease of adjustment mine has already been fettled running @ 0.9 bar on boost with fuelling matched so best to stick with the o/e fitment the replacement internal cartridge at approx £70/80 complete or alternative rebuild kits under £50.
90 BX Tzd turbo 294k SORN undergoing major surgery
90 BX Tzd turbo estate 46k awaiting surgery
65 Peugeot Boxer Van the new workhorse
52 Toyota Rav4 180k Bulletproof Jap reliability

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Re: Changing turbo

Post by rutter123 » Mon Jun 29, 2015 2:55 pm

Ok, so the eng/box are out, but this is going to be a pricey job, i have completey stripped the front end suspension, drive train etc, the list so far
Turbo rebuild, full gasket set, timing belt, water pump, thrust bearing, intermediate driveshaft bearing, 2 front wheel bearings, bottom ball joints, rear wishbone bushes, several return pipes, bottom rad hose, front strut return pipe, oils, filters, front chassis to front lower cross member needs welding, inner wing needs repair/welding, front calipers need servicing, handbrake cable,
Im sure there will be more, but on a car thats close to 300k miles, is it worth it?
90 BX Tzd turbo 294k SORN undergoing major surgery
90 BX Tzd turbo estate 46k awaiting surgery
65 Peugeot Boxer Van the new workhorse
52 Toyota Rav4 180k Bulletproof Jap reliability

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Re: Changing turbo

Post by Tim Leech » Mon Jun 29, 2015 4:43 pm

Well the new bits wont have done 300k! and its still cheaper than buying a unknown vehicle. As long as the shell is not rotten it should last for a while longer!
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ken newbold
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Re: Changing turbo

Post by ken newbold » Mon Jun 29, 2015 10:01 pm

I think Tom once went down this route changed everything, then summat happened and ended up getting rid of it.
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Jaba
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Re: Changing turbo

Post by Jaba » Thu Jul 02, 2015 12:31 am

Only you can decide if its worth it. And I think you have decided perhaps already as you have begun stripping it out already.
I would do it.
I am doing something similar on my GTi currently at 150k. Its not as bad as yours as i keep things replaced generally as I find it necessary. It had got quite smoky so I am doing engine work: bearings, rings, valve seals, new clutch and actuator conversion, PR and doseur leaks and so on.

The cost of all this is much much less than the annual depreciation on even five year old modern tinware.
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Jaba
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Re: Changing turbo

Post by Jaba » Thu Jul 02, 2015 12:37 am

ken newbold wrote:I think Tom once went down this route changed everything, then summat happened and ended up getting rid of it.
As far as I remember he required better reliability for daily commuting even after replacing everything he could think of. He then went for modern tin and sold his BX to Oscar who ran it for a while until it started letting him down following which he broke it for spares. I still have some in my dwindling stock.
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Re: Changing turbo

Post by KevR » Thu Jul 02, 2015 12:18 pm

FWIW I'm currently doing the same with the White One, which is on about 200k miles. When that's done and back on the road I'll be doing the Grey One, which is at about 210k (half of which under my ownership) and has so far been the best, most reliable car I've ever had, so I reason that I owe the old girl a bit of a facelift and some TLC.
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ken newbold
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Re: Changing turbo

Post by ken newbold » Thu Jul 02, 2015 10:23 pm

Jaba wrote:
ken newbold wrote:I think Tom once went down this route changed everything, then summat happened and ended up getting rid of it.
As far as I remember he required better reliability for daily commuting even after replacing everything he could think of. He then went for modern tin and sold his BX to Oscar who ran it for a while until it started letting him down following which he broke it for spares. I still have some in my dwindling stock.
a ford ka if memory serves
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MULLEY
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Re: Changing turbo

Post by MULLEY » Fri Jul 03, 2015 9:56 pm

They are rust heaps tbh, can't vouch for the ugly shaped new one's.
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