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Old 16-06-2017   #1
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Question Ducato 2.8 IDTD turbo removal/ increased boost

I have a 1999 Ducato cargo van or whatever the english term would be.. with a 2.8 idTD engine.. anyway, i'm in the process of fixing a broken turbo wastegate link (The small tap on the wastegate valve linkage arm, which seems to be spotwelded on the arm, broke off leaving me with an open valve and no boost at all).

My first question is - is it possible to remove the entire turbo from the car without lifting out the entire engine? I've been underneath looking at the area, and i can't see all the bolts and nust, but does anyone have experience enough to tell me i it's doable? (mechanical experience at near professional level).

Question number two: After hopfully fixing the turbo, i'm planning on installing a leak-valve on the pressure-house - wastegate-line to be able to adjust boost from within the car..
Does anybody have knowledge of how much boost this car should have originally, and how much extra it can take within reasonable safe limits?
There is not much missing, but it needs a tiny little extra when driving up the steep undersea tunnels in my area....)
Appreciate all inputs
Lagre
Lagre
Lagre
Lagre
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Old 18-06-2017   #2
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Re: Ducato 2.8 IDTD turbo removal/ increased boost

Its doable from underneath, its best to raise the van so you have enough room to manoeuvre your arms. Wire brush and use 6 sided sockets on the exhaust nuts , 12 sided usually rounds them off and have a nut splitter on hand if they are badly corroded. You may need a ring spanner for one of the nuts if you can't reach it with a socket, again preferably a 6 sided one.

When you remove the oil feed banjo be sure you don't lose the copper washers the bottom one has a habit of flying off when you remove the banjo bolt.

In terms of increasing the boost. The stock boost would be 1 bar afaik, turbo life expectancy falls exponentially with increased pressure. 1.1 bar is probably fine. I would not go past 1.2 bar.
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Last edited by corcai; 18-06-2017 at 14:09.
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Old 19-06-2017   #3
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Re: Ducato 2.8 IDTD turbo removal/ increased boost

Probably my fault not asking properly, but are you thinking relative or absolute boost...
Today, with the wastegate only blocked by a weak spring, i can get 0.15 bar relative boost, i.e. 1,15 absolute...
And that is waaay to low.. it lacks at least 20-30 hp from when it was sound...

Berfore i realized what had gone wrong, i tested the wastegate acutator with an airpump, and it opened at 1 bar relative pressure...
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Old 26-06-2017   #4
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Re: Ducato 2.8 IDTD turbo removal/ increased boost

For those with interest of the aftermath...

As previous explained, i had a failure in the wastegate actuator link... Leading me to believe i had to remove the entire turbo from the car in order to fix it properly.

As adviced in an earlier reply, i took on the job expecting a very difficult job due to the turpo's placement behind the engine, and the fact that i was going to dismantle the turbo from the manifold with expected rusty and stuck nuts.

i removed the front exhaust pipe to make eaiser access to the turbo, and then removed the inlet tube and wastegate actuator from above through theengine compartment.
I then proceeded to remove the exhaust outlet bend to gain access to one more of the turbo-manifold-nuts.

This gave me as good access as could be exptected:



Due to the better access and visibility, i could confirm that the little bolt on the wastegate arm was in fact NOT welded on as earlier assumed, but riveted on.
This in turn made me realize that i might not have to remove the entire turbo...
With a dremel and a small grinding-ball i managed to grind of the remains of the little bolt, and then with a modified plier i managed to press out the remaininglower part of the bolt:
(The bolt at the left in the picture, i planned to use a small commercial ball-link to replace the link, but wasn't able to use it...)



With access to the arm and the old part removed, it looked like this:



Then i looked throughan old nuts'n-bolt-box i had plus purchased some 4mm hex bolts and some nuts and washers to replace the broken bolt.



Put together:



After remounting the wastegate actuator and checking the operation with a air-pump, it was just a matter of remounting the rest of the parts before testdriving.
The car now has a healthy 1,2 bar relative pressure (2,2 absolute) at peak,
And runs like never before!



Lagre
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Old 30-06-2017   #5
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Re: Ducato 2.8 IDTD turbo removal/ increased boost

Update: After a 400 km trip to and from my mountain cabin, the car still runs like it should - and climbing hills in 5'th gear like never before.
Chekced the turbo repair (and tightened the alternator belt) and went for another 600+ km trip to Oslo this week with notiung to note other than a little rattling sound i suspect comes from the front mount of the front exhaust tube..
All in all it seems like success
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Old 01-07-2017   #6
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Re: Ducato 2.8 IDTD turbo removal/ increased boost

That's great , thank you for posting and very good pictures.
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Old 03-03-2019   #7
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fiat ducato 2.8 idtd 1999
Say how many xx mbar should westgate? And how many xx mbar should be inflate after an intercooler?
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Old 05-03-2019   #8
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Re: Ducato 2.8 IDTD turbo removal/ increased boost

Don't you all wish repair threads were as informative as this. Final result too and no give in and give to garage.
First class job...
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Old 07-03-2019   #9
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То що має відкриватися при 1.2мбар?
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Old 10-06-2019   #10
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Re: Ducato 2.8 IDTD turbo removal/ increased boost

Quote Originally Posted by goggs View Post
Don't you all wish repair threads were as informative as this. Final result too and no give in and give to garage.
First class job...
Massive thanks for this post and the pictures, I've just had the same thing happen to mine. Now I know what to do, A garage told me I needed a complete new turbo.
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