I finally got around to finishing up the hydraulic line replacement. I found a local shop that made me an exact replacement line for $120. I didn’t get any pictures because all I have is my phone and I was covered head to toe in grease. I filled the system with almost 5 gallons of aw32 oil and fired of the bus, moved the wheel lock to lock to purge an air and kept the fluid topped off. Overall she used about a quart less than 5 gallons. She still has an ignition relay issue and runs like poop for 5 mins till she warms up. Next thing to tackle is the massive exhaust leak at the turbo gasket and new injectors again. So that’s what I started tonight. I had to take off the entire exhaust manifold to get at the exhaust leak because the 2 bolts that where left where impossible to get loose. See pics for all the messy greasy work.
Notice the Black soot middle left, That’s where the turbo to exhaust manifold gasket should be.
So um that front exhaust stud should be threaded in and have a nut on the end, and that back area should have a stud and a nut. I can see why the exhaust was leaking, having only 2 of the 4 bolts holding it on was not doing it any good.
Getting at all the fasteners, nuts, bolts and straps is fun. This is a view from the under the bus looking up.
I’ll need to loosen the rubber Intake boot band and remove and take off the Lower oil return line here.
All the exhaust bolts came right out with the exception of the front one here between the alternator and the aftermarket oil pressure sensor. I had to take off the alternator to get that bolt. The other bolts in Cylinder 6 came out hard, the threads are a bit messed up so I’ll run a tap through it and get new exhaust bolts.
I loosened the exhaust outlet band clamp and was able to move that aside for now. That was surprising easy.
After getting the top oil feed line off, the assembly was ready to pull out. I wiggled it a bit and all the exhaust manifold gaskets fell out and the manifold/turbo assembly was ready to pull out. I underestimated the weight of this beast a bit and threw my back out a bit hoisting it out. But here it is as one bit old bit of rust and grease. Next steps are disassembly.
The turbo had no shaft play but did have this one fin that look like it took a little whack. It appears to be a tiny bit bent. Other than that the wheel was in very good shape. I bought a new one anyways and a turbo rebuild kit, because it was out and easy to work on.
Turbo Info
Soo Dirty.
Separated the Turbo and exhaust manifold and this was what was left of the original stainless steel turbo gasket. Yikes!
The gasket surface was warped a bit and looked like absolute trash. I found a Engine shop that put the manifold and turbo on the belt sander and cleaned and resurfaced the turbo and manifold for $80. Thanks Terry’s Engine! I’ll post pics of this later.
Looks fairly clean down the intake side of the turbo.
The engine bay after the manifold and turbo assembly is out.
Soo much oil and dirt buildup. Guess I’ll have to clean that up at some point. Most of the oil is from a leaking aftermarket oil pressure sensor.
Exhaust pipe to muffler and oil return line pic.
You can see the oil filter here, above that is the oil feed line hookup for the turbo and the hole where the leaking oil pressure sensor was.