1) Safety & preparation (why it matters)
- Make engine cold, battery disconnected, turbo and exhaust cool to avoid burns and fire.
- Collect tools, clean workspace, rags to prevent contamination.
Theory: turbo internals are extremely sensitive to dirt and hot-metal handling; contamination or incorrect reassembly causes early failure.

2) Confirm symptoms and isolate root cause (theory + tests — do these before teardown)
- Symptoms map to likely faults:
- Low power/slow spool + black smoke → boost loss (leaks, wastegate stuck open, actuator failure, turbine damage).
- Whine/roar + poor spool → bearing wear or shaft imbalance.
- Blue smoke/engine oil consumption → turbo oil seal failure or oil return blockage.
- Squeal/metallic knock → foreign‑object damage to blades or contact between wheel and housing.
- Quick tests and what they tell you:
- Boost pressure trace with gauge/logger vs RPM: shows whether turbo produces rated boost and where it falls off (wastegate, leaks, turbine damage).
- Boost leak test (pressurise intake side to ~2 bar / safe level) and watch pressure hold: finds intercooler/hose leaks.
- Actuator test (apply vacuum/pressure to rod): verifies wastegate movement and calibration.
- Spin the turbine (with hand when cold, no power applied): roughness/noise indicates bearing failure; free smooth spin indicates bearings OK.
- Visual external inspection for oil leaks in/around turbo, oil return line wetness, exhaust blow-by at turbine housing.
Theory: accurate diagnostics prevent unnecessary rebuilds; each test identifies the subsystem (air-side, oil supply/return, actuator/wastegate, internal bearings/wheels).

3) Remove turbocharger (ordered, with reasons)
- Disconnect intake and intercooler pipes to access compressor housing.
- Remove oil feed and return lines (catch oil; cap lines to prevent contamination).
- Remove coolant lines if water-cooled.
- Unbolt intake and exhaust flanges: manifold and downpipe.
- Unbolt actuator linkages and bracketry.
Theory: controlled removal protects oil/coolant passages and prevents debris entering turbo during repair.

4) External cleaning, then split and teardown (why each inspection matters)
- Clean exterior to prevent dirt falling inside when opening.
- Unbolt compressor housing from center housing rotating assembly (CHRA) and turbine housing.
- Remove compressor wheel and inspect for nicks, rubs, blade bend, erosion.
- Inspect turbine wheel and blades for foreign object damage, heat cracks, erosion.
- Remove CHRA and inspect shaft: radial and axial play measured with dial indicator (axial endfloat and radial runout).
Theory: visual and dimensional inspection determine whether the CHRA (bearings/shaft/wheels) can be reused or must be replaced. Small nicks on compressor may be tolerable; any contact marks or excessive runout means imbalance and imminent failure.

5) Common faults, what to replace and why (ordered by most likely)
- Oil seal / bearing failure (CHRA worn)
- Symptom: whining/roar, oil in inlet/outlet, blue smoke.
- Fix: replace CHRA or rebuild with new bearings/seals using a proper kit and precision assembly.
- Why it fixes the fault: worn bearings allow shaft radial play causing contact and oil seal failure; new bearings remove shaft motion and reestablish seal geometry so oil stays in supply/return passages.
- Turbine or compressor wheel damage
- Symptom: vibration, noise, loss of efficiency, blade tips contacting housing.
- Fix: replace damaged wheel or whole CHRA assembly (if integral). Rebalance if replacing wheel separately.
- Why: damaged blades change aerodynamic balance and flow; replacement restores correct blade geometry and prevents imbalance that damages bearings.
- Oil feed/return or crankcase ventilation faults (cause, inspection, fix)
- Cause: blocked return (carbon, sludged oil), collapsed feed lines, excessive crankcase pressure, wrong viscosity oil.
- Fix: clean/replace oil return line, clear oil feed, replace oil filter/oil, repair PCV/venting, correct oil viscosity and change interval.
- Why: proper oil flow ensures bearing lubrication and cooling; restoring flow prevents oil coking on seals and bearing seizure.
- Actuator / wastegate faults
- Symptom: overboost or underboost, stuck wastegate arm, noisy actuator.
- Fix: replace or rebuild actuator, adjust rod length to spec, check vacuum/pressure supply and boost solenoid.
- Why: the actuator modulates exhaust bypass; restoring movement returns control of turbine speed/boost to the ECU/control system.
- Housing cracks / gasket failures
- Symptom: exhaust leak, loss of boost, soot deposits.
- Fix: replace gaskets and cracked housings; ensure proper flange faces and use new studs/nuts if corroded.
- Why: sealing restores pressure containment and flow paths.

6) Rebuild/replace procedure (theory plus concise ordered actions)
- If CHRA replaced: ensure new unit is compatible and balanced for the same turbine/compressor pair.
- Theory: matching compressor/turbine geometry and dynamic balance prevents vibration and premature bearing failure.
- If rebuilding CHRA: use OEM or quality rebuild kit; follow clean-room practices, use correct press-fit tools and torque, set axial endfloat to spec.
- Theory: bearings must be installed with correct preload and clearances; incorrect endfloat causes oil seal failure or seizure.
- Replace all gaskets, seals, O-rings, studs/bolts as needed.
- Replace oil feed and return gaskets; inspect oil feed screen for debris.
- Replace actuator if suspect; calibrate rod length per spec.
- Clean intercooler and intake paths of any debris from failed turbo.
- Prime oil: before first start, pre-fill oil feed to CHRA or crank engine with fuel shut-off to build oil pressure to turbo (or crank in short bursts) so bearings get oil immediately.
- Theory: turbos run at high RPMs; dry start instantly destroys new bearings. Pre-lubrication avoids metal-metal wear at first spin.

7) Reinstallation (ordered) and torque/clearance note
- Mount turbo to manifold; torque flanges and clamps to manufacturer specs.
- Reconnect oil return (ensure gravity drain to sump without sags), oil feed, coolant lines, intake/exhaust pipes, actuator linkages, and vacuum/boost hoses.
- Replace fresh engine oil and filter if contamination suspected.
- Ensure no intake/exhaust or oil leaks.
Theory: correct sealing and torque prevent leaks and maintain geometry; correct oil path prevents starvation.

8) Post-repair verification and tuning (order and reasoning)
- Do not rev engine immediately. Prime oil, then start engine and idle; watch oil pressure and check for leaks.
- Let turbo spool under light load; listen for unusual noises.
- Road test with boost gauge/log: verify boost curve across RPM and load matches Hino spec.
- Re-check for smoke, oil leaks, and exhaust leaks after load.
- If overboost or underboost remains, re-test actuator/wastegate and intercooler/inlet hoses.
Theory: verifying ensures the repair addressed original failure mechanisms and that no new faults (leaks, misadjustment, imbalance) were introduced.

9) Prevention (theory-driven maintenance)
- Maintain clean intake filter and intercooler; prevent FOD.
- Use correct oil grade and change at intervals; monitor crankcase ventilation.
- Ensure oil return path slope and clearance; avoid long flexible low points where oil pools.
- Monitor boost and oil pressure periodically; early detection prevents catastrophic turbo failure.
Theory: most turbo failures are secondary to oil and air system problems; preventative actions stop recurrence.

10) How each repair step fixes the fault—summary mapping
- Replacing CHRA or bearings fixes shaft play/noise/oil leakage by restoring precise rotating clearances and lubrication path.
- Replacing damaged wheels and rebalancing fixes vibration and restores aerodynamic efficiency—resulting in correct spool and power.
- Cleaning/replacing oil feed/return and fixing PCV fixes oil starvation/coking and oil seal failures—stops blue smoke and bearing seizure.
- Replacing/adjusting actuator and solving boost leaks fixes under/overboost by restoring proper wastegate control and intake pressure containment.
- Replacing gaskets/housings fixes leaks and prevents exhaust bypass that reduces turbine energy and causes soot and loss of boost.

Notes & limits
- Critical dimensions and torque specs vary by turbo model; always confirm Hino workshop manual values for endfloat, radial runout limits, and bolt torques. Improper clearances or balance cannot be judged visually—use proper measuring tools.
- For severe wheel/turbine damage or burned housings, full turbo replacement is usual and often cheaper/safer than partial repairs.

That is the ordered theory-plus-action outline showing what to test, what to replace, and exactly why each repair step corrects the underlying fault.
rteeqp73

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