DIY peugeot boxer turbine repair

The turbocharger in the third generation Peugeot Boxer is one of the main units, which is designed to provide high engine speeds by supplying atmospheric air to the intake manifold and combustion chamber.

With an increase in the speed of the power unit, the exhaust gases through the exhaust manifold enter the acceleration chamber of the discharge rotor, which sucks oxygen from the air line and supplies it together with fuel to the combustion chamber.

In a diesel engine, the turbocharger plays a major role, since diesel fuel itself has a low flammability, therefore, in order for the engine to ignite and start, it is necessary to prepare an oxygen-rich mixture.

Premature turbine failure on a Peugeot Boxer 3 car can occur for a number of reasons, including:

It doesn't matter when the turbine needs to be repaired: around the clock, the Peugeot Boxer 3 can be taken to a service center for diagnostics and recovery procedures.

A turbine is a complex mechanism, it includes many parts that can break during operation, therefore, the more often the product is diagnosed and prevented, the longer the compressor will last.

The parts that are most likely to wear out include: the blower impeller, the rotor rotating from the exhaust gas, the axis of rotation, the housing. As a result of the constant exposure to high temperatures on the turbine itself from the exhaust side, the housing and internal elements become vulnerable and lose their properties. In this case, there is an intercooler to cool the air and gas, which is located next to the water radiator and, when the car is moving, cools the air entering it. In the course of diagnostics and current repairs of the compressor and lines, it is necessary to pay special attention to the indicated elements, since a negligent attitude to the parts can completely damage the car.

If, in the process of diagnosing the operation of the engine, it is precisely established that the cause of the breakdown is a faulty turbine, then a decision is made to restore or completely replace the part.

The repair of the product begins with measuring the compression on a running turbine, for which the part is connected to the supply network without an engine. In case of loss of tightness, and in the absence of other defects, all diaphragms and seals must be replaced with subsequent check.

If, during the inspection of the part, cracks and deformation of the body are visible, then the repair of this turbine is impractical and it would be better to completely replace it with a new one, since the body of the product is made of steel that cannot be restored by the welded method.

Also, the blades or the impeller as a whole should be replaced if they have chips, scratches, bends or abrasions. To do this, you need to divide the body into two halves and unscrew the retaining nut on the rod, and then remove the element from the seat. It is worth paying attention to the fact that during repair work, it is necessary to exclude the ingress of foreign objects into the turbine, since metal and other parts, when the propeller rotates, can damage the blades. Reassembly of the two halves must be carried out without misalignment or changes in inclination to avoid shaft misalignment.

On a Peugeot Boxer 3 car with a diesel engine, you can install not only original turbines, but also similar parts with suitable characteristics and seat.

During the repair, the oil is completely drained from the product, and after all the manipulations and assembly are completed, it is better to replace it completely with a new one.The lubrication change period is very important for the normal operation of the turbine, if this rule is not followed, then all units will rotate "dry", this increases the friction force and the internal temperature of the entire part.

There are several signs that the vehicle's turbocharger is in emergency mode or is defective. These indicators include:

1. Loss of engine power. Due to a broken turbine, the engine experiences "oxygen starvation", which is expressed in a mixture that is too rich in fuel and a low oxygen content in it. The fuel does not completely ignite and the engine power drops. Also, under these conditions, traction is lost, if at idle the car can work without changes on the tachometer, when the gear is switched on and the speed is increased, the engine can run intermittently or stall.
2. Extraneous sounds in the area of ​​the turbine and air pipes. If a foreign object gets inside the part, the rotation of the impeller becomes difficult, and the metal blades begin to scratch the body.
3. The temperature of the compressor oil sensor is too high. This happens when the level of lubrication is low or insufficient pressure, which indicates a violation of the tightness of the turbine membrane and that oil enters the air stream.
4. The dark gray and thick exhaust also signals a broken turbine. Due to a poor fuel mixture, the content of tar and heavy metals in the combustion products increases, the catalytic converter cannot cope with this amount and all harmful substances enter the atmosphere along with the exhaust gases.

Auto: Peugeot
Year: 2001
Model: Peugeot
Engine: 2.2 HDI

Features of the car: cargo taxi
A complaint: gray smoke from the exhaust pipe.

1. Bring the turbocharger to a professional turbocharger repair service.
2. Inspect and troubleshoot the removed unit.
3. Disassemble the turbocharger.
4. Replace worn parts.
5. Perform balancing.
6. Assemble the turbocharger.

Description of the repair process:

1. The turbocharger arrived for repair from a customer in a removed form. During the inspection, it was found that the turbocharger rotor has a slightly increased radial play, dirty oil is present in the cold snail, and soot deposits are present in the hot snail.

2. We disassemble the turbocharger, take off the hot and cold snails using a burner, disassemble the cartridge (we see the inadmissible wear of the cartridge)

3. We select a new cartridge and compare it with the old one

4. Install the cartridge in the center and check it for runout

5. Install the cartridge on the balancing stand to check the balancing and check for oil leaks

6. We select equipment for installing the cartridge on the accelerating stand to eliminate excessive vibration acceleration.

7. Install the turbocharger cartridge on the booster stand

8. Assembling the turbocharger

9. After the repair, we get a high-quality repaired turbocharger.

The price of a new original turbocharger is 2 times higher than the price of a repair with spare parts.
After repairs, it is necessary to replace all filters and oils on the car and install the turbocharger in its place.

All operations required 10 hours.
Total costs for spare parts, consumables and repairs amounted to 13800 rubles.
Guarantee on a repaired turbocharger 6 months.

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A guide for self-repairing a turbine.

The power and speed that a car with a turbocharged engine offers is a matter of principle for many drivers.

They are achieved through an integrated turbocharger, which supplies large volumes of air to the engine's cylinders, thereby increasing its power. However, the happiness of owning such a super-useful unit is overshadowed by its frequent breakdown.All car parts wear out over time, but the turbine is repaired much less frequently than a complete replacement of the damaged mechanism.

Compliance with elementary operating rules, a thorough technical inspection on time, the use of high-quality synthetic oil and its regular replacement, the correct position of the oil line without kinks, the presence of a turbo timer and the purchase of a blow-off bypass valve - these simple manipulations can increase the durability of the turbocharger several times. The opportunity to visit a service station at the slightest malfunction is not affordable for everyone, so it makes sense to master the basics of minimal turbine repair on your own.

The turbine layout is quite simple, its main elements are:

• The common body of the unit and the snail.
• Plain bearing.
• Thrust bearing.
• Distance and thrust bushings.

So the main elements of the turbine are metal (aluminum housing, steel shaft), they cannot be repaired - only replaced.

The main causes of turbine malfunction quite amenable to self-diagnosis and repair. Of course, in the absence of the necessary skills, it is better to delegate these procedures to professionals.

Almost all breakdowns are based on 2 violations: an inspection performed poorly or not on time.

• When the engine revs up, blue smoke is emitted from the exhaust pipe, which disappears at normal values.

Reason: There is a leak in the turbine through which oil enters the combustion chamber.

• Emission of black smoke from the exhaust pipe.

Cause: the fuel mixture burns out in the intercooler or in the delivery line if the control system is malfunctioning.

Reason: The drain hole of the turbine oil line is impassable and requires cleaning.

• Increase in oil consumption per kilometer (can reach a ratio of 1 liter: 1000 km).

Reason: a leak in the turbine, disconnection of the pipe joints.

• Acceleration takes longer.

Cause: A decrease in the volume of air supplied by the turbocharger due to a malfunction.

• Whistle when the engine is running.

Reason: disruption of the continuity of the connection between the motor and the turbine, air leakage into the formed cracks.

• Grinding sound when the turbine is running.

Reason: the most likely is the deformation of the unit body, self-repair is ineffective, it may be necessary to replace the entire turbocharger.

• Increase in noise level when the turbine is running.

Cause: oil line blockage, increased rotor clearances, contact between the rotor and the turbocharger housing.

• Increased fuel consumption and increased concentration of exhaust gases.

Cause: Lost connection to the turbocharger, insufficient air supply.

These include: a pipe connecting the turbine to another pipe to create an air flow.

• We remove both snails: turbine (you may need to make an effort) and compressor. We remove either with the help of a mallet - we knock down, or we unscrew the fastening bolts. We try not to hit the turbine wheel.

It is necessary to carefully examine the condition of the shoulder blades. In the presence of surface deformations, even of the smallest dimensions, they need to be replaced or repaired by grinding and turning.

1. We assess the condition of the pipe. There may be slight drops of oil on it, but ideally the tube should be practically dry. On many turbocharger models, a prompting system is attached to its port. If it is damaged or parts mismatch, there will be a significant amount of oil at the junction, as well as on the pipe itself. In this case, you will not be able to do it on your own; it is necessary to involve professionals in the repair.
2. We check the serviceability of the shaft - after removing the snails, we look for the presence of backlash - we grab the shaft with our hand and try to shift it in the direction of the axis. Half- and one-millimeter lateral backlash is quite acceptable. We also immediately check the radial backlash - the blades touching the turbine housing: we move the shaft to the extreme right state and turn the blades. When these parts come into contact, the situation indicates the need to replace the turbine due to a breakdown.It is necessary to disconnect the pipe from the intake manifold or intercooler and turbine and assess the condition of the holes. If there is a significant amount of oil in the pipe, but there is practically no oil in the area of ​​the holes, we conclude that the turbocharger is malfunctioning, accompanied by an increased oil consumption greater than the maximum value.
3. We remove the compressor wheels using pliers and a special puller, while remembering the left-hand thread on the compressor shaft.
4. We separate the sealing inserts in the cavities of the rotor and unscrew the 3 bolts of the thrust bearing.
5. We separate the sealing inserts from the retaining ring from the end of the turbine.
6. We remove the sleeve bearings, which are also attached to the circlip from the compressor side.
7. The main components, such as the cartridge, seals, rings, etc., should be cleaned and washed during disassembly.
8. Please note when buying a vehicle: the presence of a glowing inscription of the Check-engine indicator on the panel means a serious malfunction of the turbine. Only an expert can determine the exact cause of the breakdown.

• It is necessary to have a special repair kit in stock, which includes hardware, rings, oil seals and inserts.
• We check the fixedness of the nominal liners. If there are vibrations, we grind, clean, lubricate with engine oil and balance the shaft.
• The retaining rings are installed in special grooves of the cartridge inside the turbine.
• Lubricate the turbocharger liner with special engine oil and fix it in place with a retaining ring.
• Installing the compressor liner.
• Lubricate and replace the sleeve.
• From above, the sleeve is fixed with a plate using bolts.
• We install protection against dirt using retaining rings.
• Install the oil on the removable ring.
• Installing the snails.

You should be extremely careful about assembling the disassembled turbine... Often a situation arises when the analysis went quite well, but problems arise with the editing. Diligently cleaned of contamination, washed with a specially selected composition and examined for deformations (if necessary, they are replaced), the turbine parts are very carefully, until they stop, are installed in the designated grooves.

The peculiarity of the structure of the turbine - a small number of elements determines its relative durability. Its component parts are easily amenable and in most cases require replacement, but even if absolutely all parts are faulty, the turbine is capable of performing work operations. However, this fact should not be taken as a guide to action, as a malfunctioning turbine provides a truly fantastic oil consumption.

The specified sequence of operations is common for all types of turbochargers, depending on the model, some of the steps may vary. In the event of a serious malfunction, it is recommended to replace the damaged turbine.

To save money, it makes sense to master the independent repair of the turbine, especially considering that the time costs do not exceed several hours.

peugeot boxer turbine repair