This book is not written, authorized, or produced in collaboration with Garrett, Audi, or Volkswagen. This book and all of its content is produced by Brian Smothers, an independent turbocharger rebuilder. 

 

 

 

 

 

 

 

 

 

 

 

Table of Contents

Part Numbers Covered in this Guide......................................................................................................... 3

Background.............................................................................................................................................. 28

Tools and Parts Needed.................................................................................................................... 32

Glossary of Terms................................................................................................................................ 37

Disassembly............................................................................................................................................. 44

Inspection................................................................................................................................................. 67

Cleaning..................................................................................................................................................... 78

Re-Assembly............................................................................................................................................ 84

Installing the Turbo Like a Bone Head...................................................................................... 90

Conclusion................................................................................................................................................. 92

Ebay Buying Guide for Turbocharger Parts............................................................................ 94

 

 

 

Background

 

There are a number of guides to repairing a turbocharger found online. None of these guides mention checking any specs at all or re machining anything. Some of them involve using vice grips.  None of these guides are written by a turbocharger professional, they are just educated guesses.

 

It is recommended that you buy this guide before buying any other parts: your turbocharger may be ruined and you may not find out until you take it apart with this guide.

 

We have attempted to create a guide that addresses the shortcomings of the guides found online, and we have attempted to create a guide that fills the gaps that many diesel mechanics may have in turbocharger knowledge.

 

Please note, this guide is a general guide that also contains specific information regarding the GT17V turbocharger manufactured by Garrett Honeywell: the specific information regarding tolerances and dimensions ONLY relates to this specific turbo. Torque settings, machining tolerances, etc., should NOT be generalized from this guide to cover any turbocharger other than the GT17V turbos. SO:

 

Rebuilding the Garrett  GT17V turbocharger is relatively simple and easy to do under the following conditions

·      Your GT17V turbocharger does not have damage to the wheels

·      Your GT17V turbocharger does not have damage to the turbine shaft

·      Your Garrett turbocharger does not have damage to the bearing housing

·      Your GT17V turbocharger does not have damage to the compressor or turbine housing

 

The Garrett GT17V line of turbochargers is considered “serviceable” but not “rebuildable.” The GT17V is not a turbocharger that you can replace the bearings and seal plate, put it back together, re-align the marks, and it’s good to go. The GT17Vturbocharger has wear tolerances that are VERY tight, and it has balance tolerances that are VERY tight. This is because the turbocharger’s rotating components are very small, and this is because the GT17V turbocharger operates at 200,000 RPMs.

 

So, this manual and shop guide has three goals:....

 

....Tools and Parts Needed

 

Now that you know not to do this, here are the tools and parts you will need:

 

·  New turbocharger cartridge (CHRA)

·  Socket set (typically metric, but many bolts are ½ SAE), 12 point

·  Wrench set, 12 point

·  Torque wrenches (depending on the size of the turbo, you may need a wrench that reads as low as 1n/m)

·  Small flat screwdriver

·  Allen keys

·  Torx screwdrivers or sockets

·  Propane Torch

·  Penetrating oil

·  Internal snap ring pliers, large and small

·  Steel hammer (3 lb handheld sledge is best, but a framing hammer will do in a pinch)

·  Steel punch

·  Dental Picks

·  1500 or greater grit sandpaper

·  Soft face hammer

·  Motor oil

·  V blocks

·  Dial caliper

·  Bore gage

·  Dawn dish soap

·  Electric Pencil

·  Dremel Tool

·  Fire extinguisher

 

 

Recommended, but not needed

·    Wooden table

·    Shop vice

·    WCB30 rotor balancer or VSR Balancer

·    Steel straight edge

·    Oil can for motor oil

 

Frequently Asked Questions (FAQ)



Q:I have seen turbo rebuild guides on Youtube and in forums. Can't I just look at those?

A: If you want to do things wrong, definitely use those guides. Those guides are created by amateurs, and these amateurs do not know what they are doing. These free guides do not have any specs, they don't have torque settings, and they tell you to re-use parts that should be discarded. The so-called guides don't have any inspection specifications, and they are definitely wrong. This guide is written by a turbocharger professional.

Q: Do you have any other guides?

A: The author has a complete line of guides for nearly every turbocharger. Search Amazon or Ebay to find what you need.