Picked up the turbo and manifolds today, turned out to be the KKK (Borg Warner) turbo. Definetly deleteing the egr, it was nasty. Turbo may be toast anyway, doesnt turn. Sprayed cleaner down both ends, and will let it sit overnight.

 

Looks like the turbo might be salvagable, turns this morning, must have been dryed up gunk! No play end to end, but a small amount of play up and down. Im estimating this motor has 200,000 on it, so I will go ahead and rebuild the turbo while its easy to do. Looks like the kit is only $50 anyway.

 

Rebuild kit arrived today! Been searching Youtube for a good rebuild video, but none found. Got it partially disassembled, but don't have the exhaust side casing off, probably a little heat and tapping will remove it, but since there are no instructions and parts diagrams, I don't want to mess up the housing if there was another step or snap ring that needs removing.

 

Still haven't found a good youtube video on it, but I did find a good exploded parts diagram on the BorgWarner series of turbos. Also found out the K26 is used on Porsche. http://http://www.vaglinks.com/Docs/Catalogues/Melett.com_KKKCatalog.pdf

 

Finally found a good Youtube video on disassembling the turbo sections, had to go through about 10 pages of suggested videos to get to it, but finally found one!

 

Yeah, the turbine just slides off when you take the nut off....Not! A fair amount of heat and twisting, it finally came off, then I get down to the flinger thrust ring......it doesnt want to come off either! Heat helped a little, but still wouldnt budge. Finally was able to get it far enough out of the groove to put needle nose vice grips on it and pull it free with more heat. The only thing I can think of, is someone built it before, and put an oversize shaft in it. I will have to dig up my micrometer and measure it when I get a chance..

 

Oops! Said turbine! Meant to say compressor, still don't have the turbine off yet. Oversized bearings and seals are available, but nothing about a larger shaft being avaiable, doesnt look corroded or rusted, just real tight all the way down, even the washer was tight all the way off.

 

Finally got it all apart! Went back together much easier once every thing was cleaned up. Mic'ed the shaft, no wear on the turbine side, very slight wear on the compressor side. Now to get the housings back together, and the sludge out of the intake.

 

Getting everything back together, now how to plug the egr port on the manifold? The intake side is a no brainer, plate steel and a gasket, but the exhaust side is a round cast port. I found a 3/4" copper plumbing cap fits nice and tight in the pipe flange. Applied a little JB weld, drove the pipe cap in, nice easy solution.






Flange cut off crossover pipe.

 

Finally getting back on this project since I have some time on my hands. Got the turbo manifold and turbo back on, haven't started it in probably two years now. Primed the pump, hit the glow plugs, and with a cloud of smoke, she fires right off! The only problem now, is the shut down lever doesn't shut it off, it will stall it down for a second, but not shut it off. Worked flawlessly the last time I ran it. The only difference now, is I have all of the manifolds and turbo on. I know there is a thread on here somewhere about that, but I can't find it.