Please post vehicle year, make, model, turbo brand, and kit or individual part numbers you used.

It would be helpful if you recall needing any special tools.

Pictures would be greatly appreciated.


Turbo repair - rebuild parts, kits, and service data.

Wastegate actuator swap for OM602.962?




.

__________________
ASE Master Mechanic
https://whunter.carrd.co/

Prototype R&D/testing:
Thermal & Aerodynamic System Engineering (TASE) Senior vehicle instrumentation technician.
Noise Vibration and Harshness (NVH).
Dynamometer.
Heat exchanger durability.
HV-A/C Climate Control.
Vehicle build.
Fleet Durability
Technical Quality Auditor.
Automotive Technical Writer

1985 300SD
1983 300D
2003 Volvo V70

https://www.boldegoist.com/

I rebuilt a KKK - K24 from a VW 1.6 TD, but it was a long time ago, used that car for eons after that and sold it to a family member - still pulling strong.

__________________
2012 BMW X5 (Beef + Granite suspension model)

1995 E300D - The original humming machine (consumed by Flood 2017)
2000 E320 - The evolution (consumed by flood 2017)

Did a bit of that kind of work on A1 VWs many years ago. Mostly Garrett TO25s. Had a '79 Scirocco with a BAE kit with pop off valve set to 7psi (and quickly shimmed to 10-12 psi with water injection). Then later put a Callaway kit on an '84 Jetta. Used to be easy way was just to call up and get a new cartridge but anymore I hear prices have gone stupid. (By now they should have gone the other way).
When I was rebuilding, I just ordered the kits and usually regular hand tools were all I needed. Just keep everything real clean and then when installing turbo, Install drain line first. Then dump a bunch of oil in the fill hole. Then install the feed line. Crank without starting for a minute or so to get oil in feed line. I think there has barely been a time since 1981 that I didn't have at least one turbo motor. Just like barely a time since mid '80s that I didn't have a diesel. Been thinking lately that my little '84 190D would be even more fun if it had a turbo on it. Or maybe I need to find a way to graft in one of MB's new 1.8L turbo diesels into a 201 body!

I rebuilt mine late last year. I ordered a kit from one of the various sites for my garrett. I later decided to replace the turbine wheel and shaft as well as the compressor wheel. I found the parts online at turbo international but they wouldn't sell to a "normal" guy. They directed me turbo exchange in NC. I talked to them several times on the phone and they were VERY helpful.
One SNAFU. New shafts are reverse threaded so the original bolt (and the ones in rebuild kits) won’t work. Order the right one ahead of time.

Other than finding parts, the process was pretty simple. I would not call it easy. Of the work I have done on my Mercedes this was the most "cramped". There are many bolts in a small area and some of them do not want to come off

One question, are you removing the whole turbo or just the bearing housing?

I should have a few photos around I will try to put up, but nothing to informative. Mainly I thought my ceramic poweder coat job was sexy.

For special tools I needed a modified 13mm to remove some of the bolts that hold it all in. I took a spare and cut it just small enough to fit. I would have also opted for more heat (oxy not just propane) and more time soaking (I am always rushing)

Some youtube on the topic.

garrett turbo rebuild t25
https://www.youtube.com/results?q=garrett+turbo+rebuild+t25&oe=utf-8&aq=t&rls=org.mozilla:en-USfficial&client=firefox-a&um=1&ie=UTF-8&sa=N&tab=w1

garrett t25 turbo rebuild kit
https://www.google.com/search?q=garrett+t25+turbo+rebuild+kit&ie=utf-8&oe=utf-8&aq=t&rls=org.mozilla:en-USfficial&client=firefox-a


.

https://www.google.com/search?q=garrett+t3+turbo+rebuild+instructions&ie=utf-8&oe=utf-8&aq=t&rls=org.mozilla:en-USfficial&client=firefox-a

https://www.youtube.com/results?q=garrett+t3+turbo+rebuild+instructions&oe=utf-8&aq=t&rls=org.mozilla:en-USfficial&client=firefox-a&um=1&ie=UTF-8&sa=N&tab=w1

.

https://www.google.com/search?q=garrett+t3+t4+turbo+rebuild+kit&ie=utf-8&oe=utf-8&aq=t&rls=org.mozilla:en-USfficial&client=firefox-a

.

physics of turbo question
physics of turbo question

Exhaust leak between engine and Turbo
Exhaust leak between engine and Turbo OM617

87 300SDL exhaust flex coupling- where to buy?
87 300SDL exhaust flex coupling- where to buy?

Turbo Cartridge Replacement
Turbo Cartridge Replacement

Turbo Rebuild
Turbo Rebuild

Rebuilding Turbo
Rebuilding Turbo

Need help: Garrett turbo rebuild on OM617 1982 300SD
Need help: Garrett turbo rebuild on OM617 1982 300SD

Adjusting the Turbo Wastegate
Tweaking the Mercedes 617 Turbo Diesel

What causes low boost readings ?
What causes low boost readings ?

Turbocharger Wastegate Adjustment:
Turbocharger Wastegate Adjustment:

The Garrett/AiResearch turbo is harder but not too complicated; it's just a pain to get to the adjustment. There's a good series of pictures here:
Garrett Turbo Wastegate Adjustment - Benzworld.org - Mercedes-Benz Discussion Forum

Turbo boost guage advice needed
Turbo boost guage advice needed

Replacing Seals on Turbo Oil Drain Pipes
Replacing Seals on Turbo Oil Drain Pipes - OM617.9xx

W126 OM617 1985 300SD turbo drain tube gasket & seals
W126 OM617 1985 300SD turbo drain tube gasket & seals

1990 300 W124 2.5 Turbo Running worse after attempted Tune up
1990 300 W124 2.5 Turbo Running worse after attempted Tune up

93 300D 2.5L Turbodiesel Power Loss
93 300D 2.5L Turbodiesel Power Loss

.

All help is appreciated.

I am working on DIY's because it is becoming a common issue.
I have many cores to play with, KKK and various Garrett (air research) T3, T25.

.

__________________
ASE Master Mechanic
https://whunter.carrd.co/

Prototype R&D/testing:
Thermal & Aerodynamic System Engineering (TASE) Senior vehicle instrumentation technician.
Noise Vibration and Harshness (NVH).
Dynamometer.
Heat exchanger durability.
HV-A/C Climate Control.
Vehicle build.
Fleet Durability
Technical Quality Auditor.
Automotive Technical Writer

1985 300SD
1983 300D
2003 Volvo V70

https://www.boldegoist.com/