Fiat Doblo 1.9 JTD 74kW 2001: Rusty Hole in Turbocharger Pipe, Cleaning and Inspecting Turbine

Hello
When changing the oil, I noticed that I have a rusty small hole in the pipe that allows the exhaust gases from the turbocharger to come out. I tapped with a screwdriver (to cover the rust) and it made a bigger hole. It looks like:

Zdjęcie0..5.jpg Download (285.89 kB)

So I decided to unscrew the turbocharger to clean it properly and put a patch on it from the sheet. Fortunately, it was possible to unscrew it together with the exhaust manifold without major problems. It looks like this:



Zdjęcie0..8.jpg Download (293.64 kB)

Overall, it is Fiat Doblo 1.9 JTD 74kW (100KM), 2001. I would like to add that the turbine works well, it does not release oil, well, in general, it's ok.
And now I noticed such a problem, taking advantage of the fact that I have it pulled out (there is no access to do it on the car), I wanted to see how the barbell and the lever from the turbine steering wheel were moving. And here I ran into a problem. Using a lot of force, I was not able to move the turbine bulb (bar) lever. Neither one way nor the other. So I disassembled this bulb from the turbine and it turned out that the lever from the turbine blades moves completely loosely in every direction, it even flies when I tilt the turbine from one side to the other. So from what I read on other forums, I was glad because this is how it is supposed to be, it means that you do not have to unscrew the turbo and clean it, because it is just right. On the other hand, the lever in the pear is in the pressed position, and here my first question is whether after unscrewing the pear from the Turbocharger and disconnecting it from the vacuum (pear on the table), should this lever be in the pressed or extended position from the pear ??? For me, it is pushed to the max. With my hands it is very hard when I try to pull it out, maybe 1 cm, but it slips in by itself. And now, through the connector on which the vacuum hose is slipped, at the beginning I tried to suck in air with my mouth, but no reaction (anyway, the lever is still inserted into the bulb). When I tried to blow air into it, unfortunately I do not have enough strength in my lungs to push the lever out of the pear. But I tried to blow air with an 8atm compressor and the lever popped to the maximum. And here is my question, because for my taste and from what I read on other forums and watched videos on ytb, this is definitely not the case. I diagnose the turbine bulb to be replaced. But mainly everywhere there are descriptions of VW TDI engines, hardly any information on how to work it in Fiat JTD. Therefore, I am asking if it should be like this? or 100% pear for replacement. ???
The second problem is that I thought that such a pear is probably not expensive, and I will not even start a topic on the forum, but I will buy a new one right away. And here it is a shock, neither in the automotive store, InterCars wholesalers nor even in the Fiat service itself you can buy a pear for this model. Only a whole new pear turbine. (for the newer Dobli you can buy a pear, but it does not fit my model) Massacre. And there is no allegro either. Tomorrow is Saturday, I will ride the szrocikach and look for something. this is what this pear looks like:

Zdjęcie0..9.jpg Download (248.68 kB) Zdjęcie0..0.jpg Download (264.08 kB)


As you can see, it is riveted with the entire bracket that is screwed to the turbine. In these newer Dobles, two screws come out of the pear. And this idea came to my mind (but I don't know if it will fit, because the newer doble pears are bigger). Because I thought that if I do not buy such a pear, I will somehow disconnect the old one from the bracket, drill two holes for these screws from the pears for newer Dobli and try to twist it. Just like I'm saying, I don't know yet if there will be enough space, because these new Pears are much bigger. And possibly if it fits, what do you think about such a change ??? Here is a link to these pears from the newer Doblo:

http://allegro.pl/zawor-gruszka-turbiny-alfa-147-156-1-9-jtd-116-140-i6852960359.html#thumb/2

Probably soon there will be questions if I felt anything disturbing while driving. Let me put it this way, I don't drive much with this car, I drive different ones every day. Doblo, I use it more to transport something or on a further route with my friends (there is a lot of space in it). For some time just when accelerating, the car turned to the revolutions quite evenly and at 3,000 rpm I just felt a drop in power, even a momentary stopping of acceleration, but after a while it was getting slower but slower to 3,500. (I am not shooting above). For the most part, I change to a higher gear at about 2.5 thousand rpm, so this choking at 3 thousand was not a problem for me. After connecting to the computer, zero errors, zero exhaust fumes from the pipe, so I did nothing. And now, on the occasion of taking out this turb, I noticed such a problem with this pear and I would like to solve it. best regards

The "pear" is controlled by negative pressure and under its influence the tendon is pulled inside (there is no chance that you can move it sucking air with your mouth, there is a strong return spring). Correct setting of the tie rod in the VNT turbine is not a simple matter and practically impossible to do "on the table".

As for the pipe, it makes no sense to patch it, you need to replace it with a new one.

so if I understand correctly, the vacuum sucks the string to the center of the pear, so after disconnecting the vacuum, the spring should push the string away from the pear ??? And for me, you do not need to suck it in, because the tendon is pushed to the max. That is, a coo to replace .... Because with my hands, it is impossible to push the string deeper into the pear, you can only pull it back (using a lot of force), but the string slides itself to the max to the pear.

Added after 7 [hours] 9 [minutes]:

I found a similar thread on another forum, here I will paste an interesting sentence:


'' The rump works under pressure, not under pressure, under pressure in a variable geometry And did you check by attaching the coo to a compressor or a pump? Because it's the only sure way to make sure that the coo is working ''

This also applies to some VW, not Fiat. But if this is the case with me, it turns out that I have a good pear and I do not have to look for another yes

I do not remember this arrangement, look at the books where the coo is connected. On the other hand, such a failure of the pear to start working the other way round is impossible ...

Hello
The problem is solved, I close the topic . So I will describe everything one by one so that if someone had a similar problem, he would know how to solve it . I unscrewed the whole housing through which the exhaust fumes come out (the one that the rust pierced in my case), and under it there is a view:


Zdjęcie0..3.jpg Download (262.3 kB) As you can see, this turbine has no variable geometry (blades), the pear only controls this one flap. And with the pear lever pushed as far as it will go, this flap is closed. When the pressure rises, it pushes the pear cable out and the flap opens. So in my case, this pear does not work on negative pressure, only on hypertension. The air must be pumped into it, which pushes the linkage and thus opens this valve in the turbine, releasing dangerous pressure from it. So it turns out that my pear is working and I don't have to replace it . And now yes, I went to a fairly large szrocik in the area (if someone is from the vicinity of Częstochowa, I recommend the car Szrocik Bajor in Wancerzów near Częstochowa, they have literally everything there). And of course they had such a turbine all together with the pear and my rusty, hole-like element. Also from 1.9 JTD only from Brawa, not Dobel. But generally the same. There, the pear works exactly the same as for me, i.e. the spring keeps the lever fully inserted into the pear. But this is already behind us, so I didn't take a pear. Gentlemen for PLN 50 twisted me and sold the same outlet pipe, which is rusty for me. However, after returning home, I noticed a slight insignificant difference

Zdjęcie0..2.jpg Download (273.26 kB) this old pipe of mine has a bracket for two bolts, and the one from Brava does not. But everything else fits. In fact, if in Bravie you keep it all without this support and drive, it would probably also hold true for me, but I like to do everything properly, so the grinder, mig mage and please:

Zdjęcie0..4.jpg Download (228.8 kB) I cut this bracket with two screws from my old pipe

Zdjęcie0..5.jpg Download (258.31 kB) and welded to the new one ;)

Zdjęcie0..6.jpg Download (253.46 kB)


Everything fits, already twisted and working . It also looks like this. For information, I will say in 1.9 JTD 100KM and 105KM engines, there is a pear like mine, i.e. she is to pull the lever into the pear, and excessive pressure is to push it out. In these stronger JTDs there are already turbines with variable blade geometry and there the pears work on the principle of underpressure (these are the ones to which I gave the link in the first post from Allegro). The problem will be if someone breaks down a pear and he has the same model as mine, because he does not go anywhere to buy a new pear, and those from the vacuum will not fit. Only autoshoots remain, or if someone has a lot of money, a whole new turbine with a pear. Fortunately, I did without it and the old pear is ok. As I have read somewhere before, this effect of temporary gentle silting at 3,000 rpm for me may be a normal symptom associated with a fixed geometry turbine because it was their minus so small turbo-lag, the plus is that they are much more durable than those with variable geometry of the turbine blades. Best regards, thank you to everyone who became interested in the topic and I hope that this topic will be useful to someone, best regards

Your turbine is not a VNT, you don't have any steering wheels ... you just have a bypass valve which is controlled by the pressure of the turbine. You wrote about steering wheels and probably everyone suggested it without checking what kind of turbine you have there.

With a fixed geometry turbine, pressure to the bulb is connected directly from the turbine outlet (no modulating valve *). When the boost pressure exceeds the set value, the bypass valve opens and the exhaust gases gradually stop driving the turbine, only bypass it through the channel thus opened.

* - in some systems it may be, but in Doblo it is not.