Replacing 1KZ-TE turbo

[Shayne]

Should i attempt it myself or pay someone who knows what they are doing ?

 

[Sag]

From what you have already done to your motor I think you will be more than able Shayne

 

[Shayne]

Can it be done without removing the engine ?

 

[Sag]

I would of thought so as they looks room for it to come out.

 

[Shayne]

I no its tight i decided against taking the actuator off a good while ago for fear i wouldn't be able to get it back on again instead i made a slot on spacer so i could achieve the same without removing the lower bolt . I'm not even sure if it needs a turbo but i have been uncomfortable with the amount of oil in the intake since i bought the truck and instinct is telling me something somewhere is not right , I had the same feeling a few months ago but as time went on and nothing went wrong i lost interest .

I wish i could find an old school diesel specialist shop in South Wales to look at it with an expert eye but all i'm getting is big glossy pictures that inspire zero confidence .

I don't know there's no power loss , no smoke (i have turned the fuel down again since moving sensors) no leaks and nothing to indicate a problem but .........

 

[StarCruiser]

How much oil is in the intake Shayne?

In all my turbo diesels I've encountered a good coating, enough to drip up to a teaspoon full from pipes if removed and stood up. Don't forget a lot of oil mist can come from the breather system. It will regularly ooze out of hose unions (I coated mine in Orange loctite flange sealant which seams to have sealed it well). I will need a top up of oil each 4500 miles or so.

If yours is similar, I would guess you are probably worrying over nothing.

 

[Paulsven]

Can it be done without removing the engine ?

Easily Shayne. I got it down to about an hour after the sixth time I had to remove and pop it out and back in again after realising one of the gaskets had dropped out when reinstalling! There's a funny looking double copper washer thing for the union bolt which I dropped twice and a metal gasket under the turbo (oil again I think) which I also dropped a few times without realising until I got underneath to tighten the exhaust! Don't think you'll have a problem doing it but there is a knack to it.

 

[Shayne]

Your probably right Starcruiser i'm not expecting any imminent catastrophic failure i just feel there is something going on that can be nipped in the bud now . I haven't had reason nor opportunity to put any miles on the truck since the coolant conundrum presented itself so the question is still an open one and i've wasted far to much sleep putting together a plan of attack should the coolant loss continue . I did not know that the turbo on these is cooled by oil AND water until after midnight last night which led to me posting this question .

The turbo works to well to be faulty so it's probably a turbo seal or gasket but if its got to come off - well i only expect another 870,000 miles out of the truck so ...

Thanks for that Paul its exactly the sort of response i was hoping for i'm sure its a pita of a job so front wheels off to lower the truck for me as its a bloody miracle i haven't broke a rib yet when the beer crate i stand on to see into the engine bay slips out from under me , i'm only 6ft 1

 

[Sag]

Your probably right Starcruiser i'm not expecting any imminent catastrophic failure i just feel there is something going on that can be nipped in the bud now . I haven't had reason nor opportunity to put any miles on the truck since the coolant conundrum presented itself so the question is still an open one and i've wasted far to much sleep putting together a plan of attack should the coolant loss continue . I did not know that the turbo on these is cooled by oil AND water until after midnight last night which led to me posting this question .

The turbo works to well to be faulty so it's probably a turbo seal or gasket but if its got to come off - well i only expect another 870,000 miles out of the truck so ...

Thanks for that Paul its exactly the sort of response i was hoping for i'm sure its a pita of a job so front wheels off to lower the truck for me as its a bloody miracle i haven't broke a rib yet when the beer crate i stand on to see into the engine bay slips out from under me , i'm only 6ft 1

Been only 5ft Shayne I sit on the engine as can't reach top of wing from the floor let alone engine bay

 

[Shayne]

of course you did explain to the mrs that a suspension lift helps tremendously with height issues didn't you

 

[Beau]

Shayne, The turbo can be replaced inside the engine bay, not the easiest of jobs but possible. Regarding your turbo and oil in the intake pipes. It's probably nothing major, I had a light coating on mine, nothing that would drip loads. If you're losing noticeable oil now, then there's a problem....

 

[Sag]

Never thought of that il give it a go.

 

[Shayne]

Beau you bugger where have you been ! Its 2.40am and resigning myself to another sleepless night mulling this over i have a new theory that i would appreciate your thoughts on

 

[Shayne]

Bearing in mind my truck is now far more powerful than it was ever meant to be , and the egr is blocked and throttle butterfly removed - could the mystery be crankcase oil is messing up my fuel air ratio which could be cured by fitting a catch can ?

 

[Shayne]

Well there you go a few hours of reading reveals vented crank air/oil is recirculated to keep bureautwats happy same as the EGR , and all heavy plant , wagons etc have an oil/air separator to protect the engine from consequences that make the unwanted effects of EGR seem almost benevolent !

 

[Paulsven]

The biggest problem I had was when reinstalling the exhaust manifold. It looks like it just bolts straight on and off but don't be fooled! The flexible bellows in the middle springs which means lining bolt holes up is a bugger. It nearly brought me to tears at one point as I fought to line everything up. I could either line up cylinders 1+2 and the turbo but not 3+4, or 3+4 and the turbo but not 1+2 etc etc. You also then have the egr pipe aroung the back to line up too! If you're blanking your egr it might be an idea to fashion a blank to bolt on the exhaust manifold (and another the other end) and remove the egr pipe altogether. (that's what I was thinking of doing anyway).

There are 3 bolts for the exhaust manifold to the turbo, one of which is buried in amongst the exhaust manifold which I also found a pain but managed it by using a 1/4" drive (i think) socket and extension as I couldn't get anything else in there as it was too fat.

As I said earlier, there is definitely a knack of knowing what to leave loose to give you wiggle room to line things up, what has to be tightened first as you won't get to it later and what tool combinations will get to the awkward bolts.

Definitely doable but don't lower your truck too much as you will be sliding underneath as well as working on top.

Oh and if you are thinking of replacing gaskets from a "full engine" gasket kit don't be fooled as you probably won't find them in there!

 

[Beau]

Well there you go a few hours of reading reveals vented crank air/oil is recirculated to keep bureautwats happy same as the EGR , and all heavy plant , wagons etc have an oil/air separator to protect the engine from consequences that make the unwanted effects of EGR seem almost benevolent !

Shayne, it's been a little hectic my side making these large few arrangements for my truck shipping over. Just found out they wont take delivery of it on a Saturday which I had planned with Trevor, and now it looks like I may need to think of something else!!

Regarding the crank case air, on these engines, these a simple hose that connects to the top of the engine down back to the sump. Fitting a catch can in line will remove the heavy oily deposits. However I can't get my head around how this crankcase oil is ending up in the intake?

 

[Shayne]

Cheers Beau i could find precious little info about the vent on a 1kz and it may be as you say but i do struggle with how a straight in and out pipe can be considered a vent , surely that bleeds no pressure at all Most of what i read comes from yank big diesel Fords which allow blowby to recirculate through the turbo . My trucks not here to investigate and its pissing down in any case .

I hope you get transport for your truck sorted i would be glad to help but its a fair distance for me and i doubt my licence will allow me to tow a vehicle and trailer .

 

[Trevor]

Shayne, it's been a little hectic my side making these large few arrangements for my truck shipping over. Just found out they wont take delivery of it on a Saturday which I had planned with Trevor, and now it looks like I may need to think of something else!!

Regarding the crank case air, on these engines, these a simple hose that connects to the top of the engine down back to the sump. Fitting a catch can in line will remove the heavy oily deposits. However I can't get my head around how this crankcase oil is ending up in the intake?

PM sent Beau, all will be well mate.

 

[Beau]

Cheers Beau i could find precious little info about the vent on a 1kz and it may be as you say but i do struggle with how a straight in and out pipe can be considered a vent , surely that bleeds no pressure at all Most of what i read comes from yank big diesel Fords which allow blowby to recirculate through the turbo . My trucks not here to investigate and its pissing down in any case .

I hope you get transport for your truck sorted i would be glad to help but its a fair distance for me and i doubt my licence will allow me to tow a vehicle and trailer .

From my understanding, when the pistons are moving up and down, the air moves to quickly and can't be replaced as quick on the down/up stroke hence the need for the crankcase vent system. It's meant to balance things out and cause no pressure/vacuum. Some cars plumb there system different to others but I'm pretty certain on these trucks they go back into the bottom end. At least they're not as complex as the PVC systems on European cars. Vacuum lines everywhere!

I reckon your turbo's fine. Monitor oil usage and smoke out the back. Thanks as well. Just spoke to Trevor who's managed to still help me out, Legend!