Huston...we have a problem

[Functional Artist]

Turbo Autopsy

I took the Turbo unit apart ta try-n-see what happened

The first thing ya can see is the "fins" on the "cold side" (or air "in") side of the impellor are kinda busted up

...& the whole impellor & shaft are just floppin' around
* Notice the "gap" difference between the upper pic & this lower pic?

...& ya can see where the impellor was scraping on the inside of the housing
* Notice this outer (cold side) housing still has motor oil in it (it's not supposed to)

Here is a quick little video
https://www.youtube.com/shorts/k3pYai32i9A

 

[Denny]

I wonder how much of the damage was before or after the engine finally shut down since you are supposed to idle a turbocharged diesel for 5 minutes before shut down to avoid bearing and seal damage.

 

[Functional Artist]

I wonder how much of the damage was before or after the engine finally shut down since you are supposed to idle a turbocharged diesel for 5 minutes before shut down to avoid bearing and seal damage.

Hey Denny,

IDK
Hopefully get the gasket tomorrow
...& then, we gonna find out

I worked on dia-sectin' the Turbo a bit more

* Notice I'ma usin' a 36" long breaker bar
...it's for 3/4"drive sockets

So, I converted it down to 1/2"
...then, converted that down to 3/8"
...added a ~4" extension
...& then/finally, a 12mm socket

Some bolts co-operated
...& some didn't

** Hey, I told 'em up front "we can do this the easy way"
..."or...we can do this the hard way"
...but, we gonna "do this"

So, those who didn't co-operate
...paid the "price"

Here is what it looked like, inside of the "hot side" exhaust out, chamber
...before I removed the impellor & shaft

So, it seems like "fresh" air, coming into the "cold side" starts that impellor "blade" ta spinnin'
...then, the outgoing "flow" of exhaust gases spins this "hot side" impellor "blade"
...which then, works ta "spin" the "cold side" impellor "blade"...even faster
...which starts increasing the incoming air...even more
...& Woooooooooshhhhhhhhh

Exploded view
* The "culprit" (bad part) is the "piece" in the middle, with the "flat" disc

This is a pic, of the "hot side" of that "piece" in the middle, with the "flat" disc
...& (in the center) would be the "suspect" bushing/bearing/seal
...it looks kind "wollar-ed out" (technical term) ta me

 

[Functional Artist]

The exhaust manifold gasket came in yesterday afternoon
...so, I got back to working on the truck

Before pic
* Notice the broken bolt/stud
...still had ta get that "little guy" out

After gettin' the broken stud out, I maneuvered the Turbo & manifold into place
...& (temporarily) "hung" it with a couple of the mounting bolts

Then, I pulled one of the bolts out
...& slid or "tucked" the gasket "in place" (on one side)

Then, pulled the other bolt out
...adjusted the gasket down "totally" into place
...& then, installed the other (6) bolts

I also, cleaned as much of the motor oil, out of the "air" system, as possible

There really wasn't a whole lot in there

...& after ~6 hours, I successfully got everything back together

Then, after ALL of that
...when I went to start it
...it "cranks over" like crazy
...but, it wouldn't/didn't "fire up"

 

[Denny]

I’m sorry. Probably low on compression?

 

[Master Hack]

Oh No!

 

[Denny]

Now whats the plan?

 

[Denny]

Another thought. Did you pull an injector to see if it was giving a squirt of fuel? Maybe a pump failure?

 

[Functional Artist]

Another thought. Did you pull an injector to see if it was giving a squirt of fuel? Maybe a pump failure?

Hey Denny,

Todays Update
First, I put a couple of gallons of fresh diesel fuel, in the tank...just to be sure
...then, bled the fuel system...just to be sure
...& got plenty of fuel up to the (2) "Bleeder Points" (that's a "good sign")

So, I know that we have fuel, in the tank
...& we are getting fuel, up to the injector pulp
...but, she still wouldn't start

Next, I removed (1) of the injector lines...right at the injector
...& then, "cranked" 'er over
...& got fuel shooting out of, the end of the line (that's another "good sign")

So, I put 'er back together
...& tried 'er again
...but, she still won't start

Next, I (& you're NOT really supposed to) sprayed some starting fluid into the air cleaner/air intake
...& "cranked" 'er over
...& it "fired up" (even "better sign")
...but, only "ran" for ~ 3 seconds
...&/then, stalled

Wow!...that was...somethin'
...gotta try that again

I (& you're NOT really supposed to) sprayed some starting fluid into the air cleaner/air intake, again
...& "cranked" 'er over, again
...& it "fired up" (for ~ 3 seconds) again (another even "better sign")
...but/then, stalled, again

Now, I'm thinkin' that...maybe...the injectors have gotten...IDK...like "fouled"
...or the "ends" like "coated" or clogged from that "oil fueled runaway incident"
* Think this is a possibility?

I'm pretty sure that I switched the ignition "OFF"
...so, the Diesel fuel was "shut off" (not flowing) while the engine was "running" (as seen in the video) for a couple of minutes

Movin' on...
I tried pulling (1) of the injectors out (to try-n-see how it looked)
...but it wasn't co-operating

I wasn't 100% sure how they "came out"
...& I didn't want to break anything

So, I went back to the parts engine
...& worked on pulling the (4) injectors out of it (research & harvesting parts)

It was getting late
...& I was kinda getting frustrated
...so, I'm going to get at 'er again, tomorrow

I didn't take any pics while workin' today (kinda concentrating)
...but, this evening I took a few pics of the injectors that I took out of the parts engine

This is a close up of what the "tip" or end of the injector looks like

 

[Denny]

I hope the force is with you. Running is a good sign. Hope the injectors do it for you.

 

[Functional Artist]

I hope the force is with you. Running is a good sign. Hope the injectors do it for you.

Hey Denny,

Todays Update
The (4) injectors that I "pulled" out of the "parts" engine (yesterday) came out pretty easily
...(1) I just pulled out by hand (after removing the "hold down" & nuts)
...& the other (3) "popped" out with a just a bit of leverage, from a regular screwdriver
But,
The (4) injectors that are in my truck are being an F'in "Bear"

After a bit of research (on how ta remove diesel fuel injectors) I found that they sell a "puller" to remove them
...which is "basically" just a "slide hammer" that comes with a variety of (metric) threaded ends
But,
No one carries that "puller" around here
...& "if" I ordered (1) it wouldn't even be here until like Sunday (4 days)

So, I rounded up a body work type of a slide hammer
...& it had a "Notched out/box hook" type of an "end" in the box
...that would work with one of the metric bolts that I have left over from "pulling (3) Turbo units
But,
Them SOB's still wouldn't budge (technical term)

So, after "thinkin' it thru" a bit more, I "rigged up" a kinda mechanical "reverse press' type of a thing
...that used a couple of bolts to mechanically "lift" "em out (got (2) out so far)
...but, they didn't come out easily (actually, fought me the WHOLE way)

Time for Pics
The (2) injectors on the left, came out of my truck (today)
...the (1) on the right is (1) of the replacements, from the "parts" truck ("pulled" yesterday)

* Notice the "crud" on the "shafts" of the (2) on the left (from my truck)
...especially around the bottom

Here's a close up

Here is an "extra close up" of the "tip" of the far-left injector
...pretty "cruddy" lookin'
...& notice the hole? ...WTF?

Here is an "extra close up" of the "tip" of the middle injector
...pretty "cruddy" lookin'
...& the "end" looks kinda burnt

Here is an "extra close up" of the "tip" of the far-right injector

I believe this is what they are supposed to look like

 

[Master Hack]

Dem injectors look done for, and l really don't know much bout oil burners.
how many miles did it take to get there?

 

[Denny]

I agree, you got your money out of them.

 

[Functional Artist]

Dem injectors look done for, and l really don't know much bout oil burners.
how many miles did it take to get there?

Hey T,

This truck is a 2003 Isuzu NPR-HD with ~200,000 mi. on it
...technically still kinda young (for a Diesel)
...or maybe considered middle aged

 

[Functional Artist]

I agree, you got your money out of them.

Hey Denny,

The looks of these injectors
...would seem to co-oberate the oil fouled theory

I really don't "see" how they could have "operated" in this condition

 

[Denny]

Not only do they look burned but kind of worn also. They don’t last forever. If you put Vaseline heavily on the o rings when you reinsert them they won’t usually tear up the o rings and go in easier. Clean everything up with some scotch brite.

 

[Master Hack]

I really don't "see" how they could have "operated" in this condition

No kidding! So can ya do a compression check? Through the injector hole?

 

[Master Hack]

you put Vaseline heavily on the o rings

Wadda bout never sieze?

 

[Denny]

No, never seize does not work because it will not melt out and allow the o rings to seal. You can use it on the bolts though.

 

[Functional Artist]

Yesterdays Update
It took me at least (4) hours to get that last "stupid" injector out

It was seized so bad that I broke the "top" bolt (the bolt for pulling the injector)
...then, tried drilling it out (which was successful)
...but, the "piece" of the broken bolt, still wouldn't come out
Well, "there goes" Plan A

Plan B
I made a "C" type of a clip that would "fit into" a "grove" in the top of the injector (to "bypass" the broken bolt)
...but, there was so much pressure that the "C" clip broke

Plan C
I welded the "puller" to the top of the injector
...but/then, broke the DIY puller that I "rigged up"

Plan D
I had to repeatedly soak, around the top of the injector, with penetrating oil
...& then, using various tools like a hammer, a box end wrench, vise grips & even a short piece of pipe
...I had to try-n-work the injector back-n-forth (twisting it, in the hole)
...& FINALLY got that SUCKER out (the (1) on the right)

Notice how heavily the "shaft" is crusted up?

Here is what the injector area looks like (after reassembly)

Yup, the "tough one" was that last injector (far right) with ALL of the crap (EGR valve & pipe) around it

Injector info
The line coming into the side is the "main" fuel line
...the "top" line is the extra fuel return or bypass fuel line
...& it is held in a retaining bracket & (2) nuts