Turbo Removal, Advise pleas!

[az88turbo]

Hi all,

I intend to remove my turbo on Sunday so I would appreciate any advice you could give me.

I am removing it for a rebuild based on the following (hope I have it right?):

- 24k miles
- Engine using excessive oil (about half a quart per hundred miles)
- Plugs are clean and no sign of blackening from burning oil
- No blue or black smoke from exhaust
- No oil in turbo air intake or injector intake from turbo charger
- Boost from turbo down

From the above I am assuming that the exhaust side seal has gone and the oil is leaking from there and blowing out of the exhaust (I have seen a splattering of what looks like oil on the floor a couple of times).

Questions:

1. Do you think I have made the correct diagnosis? (with help from the local turbo shop guy).
2. What would be the best way to remove just a pipe from the exhaust side to check if the diagnosis is correct and there is oil in the exhaust side of the turbo.
3. Do you have any suggestions on the easiest way to remove the turbo (it doesn’t seem to show how to remove the turbo in the repair manual, strangely enough).

All help is much appreciated.

Thanks,

Mark (AZ88Turbo)

[lotusespritworld]

Sounds like that could be a problem with mine. Be very interested to hear how you get on. Email me what you find out [e-mail].

Can't help with the actual removal, but I've had the pipe of when I replaced the cat. Check the link below, it may help

kato
Lotus Esprit World


www.lotusespritworld.com/EMaintenance/Exhaust_install.html

[cnh1990]

Disconnect the exhaust pipe just ahead of the muffler and before the cat. Run your finger inside the pipe and see if there is oil in there if you can't see it. Should be pretty dry in there if not. Proceed with the turbo removal for service. At this time think about a ball bearing upgrade instead of the stock ones.

Not too much to remove the turbo. 2 oil lines and wastegate connections other than the bolts that hold it on the exhaust manifold and cat back exhaust.

Calvin

[lotusespritworld]

What's involved in replacing the seal? Is it something that can easily be done at home?

I've got a lot of dirt/oil on the underside of my turbo, so maybe I've the same problem. Been kicking a little oil out of the exhaust as well, only using a little more oil.

kato
Lotus Esprit World

[az88turbo]

Thanks folks.

I'll post the results as soon as I have completed the check/removal.

Mark

[cnh1990]

Unless you have a machine shop it can not be done at home. I maybe wrong but I believe the bearings and seals are pressed in with a hydraulic press.

Also the impellers need to be finely balanced due to high rpm. Best leave it a turbo shop it is not something that either Jim or I would attempt.
Calvin

[lotusguy]

Mark,

I concur with your diagnosis. First, soak everything overnight with lots of penetrating oil. Next, with a large bladed screwdriver, bend back the safety tabs keeping the mounting bolts on.

You will need several wrenches (13mm I believe) and sockets, U-joints to get at the bolts involved. You will still end up with a couple nuts which require that you use an open ended wrench turning 1/6 turn at a time (very tedious).

Lotus uses crush nuts which distort the threads on the studs rather than employ a lock washer or such, so plan on them being extra tough and also plan on replacing the studs. You may need to cut the bolts on the turbo intermediate pipe as these usually freeze beyond penetrating oil or application of heat.

Remove the oil supply lines and you'll be able to remove the turbo. Happy Motoring! Jim '85TE

>> Edited by lotusguy on Sunday 20th April 09:50

[az88turbo]

Jim,

Thanks for the instructions.

Do I need to remove the part of the trunk that is next to the turbo? Or do I have to remove the whole bottom of the trunk to do that?

[cnh1990]

Check the cat side pipes for oil before removing the turbo.

[lotusguy]

az88turbo said: Jim,

Thanks for the instructions.

Do I need to remove the part of the trunk that is next to the turbo? Or do I have to remove the whole bottom of the trunk to do that?

Mark,

Removing the trunk floor is going to be helpful, but it's no small task in it's own right. Happy Motoring! Jim'85TE