Turbo not working

[Tanz]

The amount of boost showing on the gauge has reduced in recent weeks to the point where it hardly registers. Checked the earth and other electrical connections and all is OK in that respect.
Tried to move the wastegate actuating arm but it was solid and where the arm connects to the turbo it was very rusty. I couldn't make out the circlip at the end of the arm due to rust. Eventually got the actuator out but not without damaging the end. See picture below




I have ordered some 5mm bar and a rod connector so will try to join a piece to the existing rod. Distance from the face of the unit to the centre of the hole is exactly 100mm.
Has anyone else done this?
The rod moves when I apply air pressure to it using a electric tyre pump so hopefully it is saveable.

Is the car driveable with the waste gate removed and the vacuum connection plugged?

[Tuga2112]

if that was me, i would be keeping it simple and welding a small piece of sheet metal over the damaged section and drill a hole in the same location.

as far as driving, you can check the manuals and find out if what you suggest will make the turbo spool uncontrolably (not safe) or not boost at all (i suspect safe ? but im sure someone will correct me)

[Tanz]

if that was me, i would be keeping it simple and welding a small piece of sheet metal over the damaged section and drill a hole in the same location.

as far as driving, you can check the manuals and find out if what you suggest will make the turbo spool uncontrolably (not safe) or not boost at all (i suspect safe ? but im sure someone will correct me)

Hi Tuga2112 and thanks for the reply. To late to weld a piece of sheet metal on. I have already connected a new piece of 5mm bar and my son has taken it to work to heat and flatten the end in a press. He makes parts for Classic Jags so he has the equuipment for doing this sort of thing. Will post a picture when it is finished. By the way, I subscibe and enjoy your videos - thanks for those.

The car has its MOT on Wednesday and as the turbo is not part of the MOT I was hoping to get the MOT out of the way.
My problem now is getting the spindle out of the arm. Should be a circlip but I can't see it. With the waste gate arm removed, should the small spindle in the middle be able to be pushed out making the circlip easier to remove? Suspect the whole thing is rusted solid. I obviously have not been driving hard enough and making the waste gate move!!





Image looking undernieth using a mirror - hard to see a circlip?


Any tips on how to get the pin out while the tuurbo is still in the car welcome

[Tuga2112]

i never had to look at that specifically.
but since your asking for ideas.
1 - sometimes its easier to access undernearth (although you cannot see it at all)
note - its worth a go, but i had to do the wastegate wiggle in the past. and from undernearth it didnt really help much
2 - there is a tool that is a needle nose plier, but with a "bent" nose. they are designed like that. and i use mine on a regular basis around cars. something like this, maye be of use

i dont really know where mine came from. and i would like to purchase a set of 3 with differnet lenghts, but its one of those that i havent put the time into ordering online. (when i checked i found the prices a bit silly )

[Steve A]

Phil, the actuating arm usually has a small shaft connected at 90 degrees on the end which goes through the waste gate actuator.
It looks like your “small shaft” is still located in the waste gate actuator. So it’s broken away which would explain the way it looks ripped open.

[Steve A]

You can see the “C” clip in the photo, you can get to it from getting under the car and looking up a small terminal screwdriver will get it off and some decent long nose pliers to pop it back on.you need to get the shaft off and reattach it to the actuator arm.

[Tanz]

Phil, the actuating arm usually has a small shaft connected at 90 degrees on the end which goes through the waste gate actuator.
It looks like your “small shaft” is still located in the waste gate actuator. So it’s broken away which would explain the way it looks ripped open.

Yes, thats it exactly. Problem is I can't get the 'small shaft' out of the waste gate actuator. If you look at the picture above which uses a mirror, where is the circlip? Should that small shaft push out a bit so making it easier to remove the circlip?

[Tanz]

You can see the “C” clip in the photo, you can get to it from getting under the car and looking up a small terminal screwdriver will get it off and some decent long nose pliers to pop it back on.you need to get the shaft off and reattach it to the actuator arm.

Thanks very mch for the info Steve. I will get under the car and give it a go tomorrow but as you can see from the pictures, the circlip isn't really visible. It seems to have rusted into the pin.

[Steve A]

All things being good you will hopefully look up at the turbo and see the "c " clip,
I have a piper down pipe so that might make it easier or more difficult (can't remember).
Because your actuator arm isn't connected the waste gate will be flapping about which will make it
more difficult to do.

[Tanz]

All things being good you will hopefully look up at the turbo and see the "c " clip,
I have a piper down pipe so that might make it easier or more difficult (can't remember).
Because your actuator arm isn't connected the waste gate will be flapping about which will make it
more difficult to do.

Got under the car this morning but no joy. I can reach where the c clip should be but can't make one out. It looks like it does in the 4th picture above - the one with the mirror. Either the c clip has corroded to the point that it is not distinguishable or it is missing and a previous owner has just mushroomed over the end of the pin to stop it falling out.
Should the pin move ie turn? It is locked solid on my car. I have cleaned the c clip area with a small wire brush several time and sprayed it with plus gas. With the waste gate rod removed, surely it should be possible to push the pin down so you can see the c clip on the end of the pin? The pin won't move at all.

[Steve A]

I think even if the turbo was off the car and held in a vice this would be a difficult job,
So its location is making it almost impossible.
The trouble is you really want to get the pin out without damaging the hole it sits in.
I’ll go and look at my car and see if I can draw inspiration

[Steve A]

Due to the tight access, I can't really see you being able to get a fair crack at this, without the potential of damaging the turbo
If it was me I'd be looking at maybe getting a hacksaw blade in there and try and cut the top off the pin, but if it starts spinning then you're sunk,
this would be a very long job.
It could be turbo off, if it's due for a refurb , then that's kind of a positive, I know a good firm if you do, and they'll take the pin out all in the cost.

[Tuga2112]

is removing the turbo a dificult job ?
from my understading the refurb job and parts are neither dificult or expensive, the reason i havent done it, is simply the fact i am pretty sure i dont need it, but that comes from a point of ignorance topped up with the fact i get no symptoms at all of any problems.

[Tanz]

Due to the tight access, I can't really see you being able to get a fair crack at this, without the potential of damaging the turbo
If it was me I'd be looking at maybe getting a hacksaw blade in there and try and cut the top off the pin, but if it starts spinning then you're sunk,
this would be a very long job.
It could be turbo off, if it's due for a refurb , then that's kind of a positive, I know a good firm if you do, and they'll take the pin out all in the cost.

Thanks for your help. I was going to look at the wiki to see how to remove the turbo it but it says 'under maintainance'. The pin doesn't move at all. If I sawed the top off, the rest of it would still be stuck in the hole. I will have another go at it tomorrow. If the turbo comes out it would at least be an oppertunity to tidy up that area and as you say, could get it refurbished.
On the positive side, it passed the MOT today. The CO was high so I had to go to the garage and adjust the CO adjuster behind the glove box.

[Tanz]

is removing the turbo a dificult job ?
from my understading the refurb job and parts are neither dificult or expensive, the reason i havent done it, is simply the fact i am pretty sure i dont need it, but that comes from a point of ignorance topped up with the fact i get no symptoms at all of any problems.

My only worry is access to some of the bolts and the bolts being rusted in. Got visions of rounded off bolts and nuts!!

[Steve A]

I've removed my turbo a couple of times over the 15 odd years I've had my Elan, it helps when you're a tradesman, you have the correct tools etc.
On another car I might have had a nightmare, studs breaking (quite common), tradesman or not it will break for anyone wielding the spanner.
Lucky for me I didn't have any break, but did have a few seize up wrecking the thread on the stud.
Good luck with yours

[Tuga2112]

My only worry is access to some of the bolts and the bolts being rusted in. Got visions of rounded off bolts and nuts!!

I Have sheared off 2 of the heatshield bolts over the years when doing other tasks in the area. its not a good starting point in my case.

[dapinky]

[
Thanks for your help. I was going to look at the wiki to see how to remove the turbo it but it says 'under maintainance'. The pin doesn't move at all. If I sawed the top off, the rest of it would still be stuck in the hole. I will have another go at it tomorrow. If the turbo comes out it would at least be an oppertunity to tidy up that area and as you say, could get it refurbished.
On the positive side, it passed the MOT today. The CO was high so I had to go to the garage and adjust the CO adjuster behind the glove box.

In the absence of the wiki. if you look on the 'manuals' website the procedure for removal and refurb of the turbo is on there - under the 'IHI rebuild' page. Together with the workshop manual, it is all you will need to know (and all that is on the wiki!).

[Tanz]

Thanks for all the help guys - will have a look at the manuals page.

[Tanz]

The discription on the manuals page is excerlent! Will come in very handy if/when I remove the turbo.
Kits to rebuild the turbo seem quite cheap assuming i'm looking at the right thing https://www.amazon.co.uk/Turbocharger-N ... 167&sr=8-1

I have repaired the waste gate actuator - just needs a hole drilling on the flat end when I know what size to drill it. Needs to be accurate so will use the pedistal driller.
Fixed it getting some 5mm stainless bar and a connector. Cut a thread on each end and heated the end then flattened it in a press. The hole is exactly 100mm from the face of the unit