I am getting ready to pull a lot of stuff apart and the turbo will come out too. Good chance to give it a rebuild (at160k) while I'm at it. I am however not 100% sure what turbo is stock on 2000 S40 US models. Is it the mitsubishi TD04?
Also: best rebuild kits from G-Pop Shop? Or does it matter?

 

To answer my own question (after thorough research) and as a reference for others: 2000 Volvo S40 1.9t (US model) with a B4204T2 engine has a Mitsubishi TD04L turbo in it.
I bought a rebuild kit from ecrater.com from a seller named tradergreg for under $50 shipped. It includes everything you need to rebuild including thrustplates for flatback and superback turbos.

There is a good tutorial on YouTube about how to rebuild a turbo here: How to Rebuild a Turbo - Part 1 of 2 - YouTube
Its a rebuild of a TD05 but it applies to the td04 as well and also to many other types of turbos.

 

Great info. Thank you! I have a 2000 V40 with the 1.9T engine that I've owned for about a month. I'm going through it fixing small problems. I put my Mityvac on the turbo vacuum actuator this afternoon and the actuator did not move. So I'm looking for a new actuator. Do you have any ideas? Thanks!

 

Unless the turbo is burning or leaking oil BADLY I recommend you NOT rebuild it.

 

If by actuator you mean the waste gate actuator then a vacuum will do nothing to it. It actuates with pressure, not vacuum.
I have just finished a complete upper engine rebuild including turbo on mine and it was very necessary. The whole intake system including manifold was contaminated with oil and carbon deposits and the turbo was extremely encrusted with carbon and leaking oil. The turbine/compressor wheel assembly had a lot of play and needed new bushings badly. I think another 1000 miles and the turbo would have desintegrated.
However, the turbo turns at very high speeds with very small tolerances and if you make any mistakes during the rebuild it is likely to destroy itself. If you rebuild it, be sure you know what you're doing.

 

I dug up some pictures of my rebuild or rather the "before and why"

The compressor wheel. I had already cleaned off a little bit of the carbon deposits with carb cleaner before I took this picture but you can still see the black color on the wheel and the deposits on the housing.


This is the turbine wheel with the shaft and somewhere under the black crust is the oil seal...so they say. Notice the darkening of the shaft, seems like it got a little hot too. Also, the bushing (the golden piece) was worn out, allowing the shaft some severe sideways motion, just under self destruct.


Next up we have the housing on the turbine side under the heat shield. Besides the carbon deposits pay special attention to the crusty and rough surface inside the hole. That's where the seal is sitting. I wonder why there was oil everywhere.


Lastly here is a picture of the cleaned up parts with new seal on the shaft. The turbine wheel has not been cleaned yet in this picture.


Besides the damage found in the turbo I also found oil and carbon deposits all the way through the intake system, intercooler pipes, intake manifold etc.
The intake manifold had a nice layer of black baked on carbon deposits on it.

 

That's annoying as I've already ordered a new actuator from Japan. I'm familiar with Garrett turbos on Volkswagen diesels which have vacuum actuators. I don't know anything about pressure actuators. So....where does the pressure come from to drive the actuator?

 

I'm sorry to hear that. The pressure comes from the boost control solenoid. It is mounted on the rear of the air box and has 3 small hoses coming out of it. Once the turbo creates more than a certain amount of pressure the control solenoid let's the pressure get to the waste gate actuator which opens the waste gate to avoid over pressure. When I rebuild the turbo I used pressured air from my compressor to test the function of the solenoid. I'm not sure if the vacuum pump you used can create pressure too but some canned air should do the trick. Don't use too much pressure when testing, you don't want to damage the actuator.

 

Thank you for the great information. I think I've got this under control now. I was able to cancel my order for the new actuator. My problem is I'm familiar with Garrett variable vane turbos that are vacuum actuated and have no waste gate. This turbo is completely different.

 

Wouldn't happen to know the T designation would you? I.E. 12T, 14T, ETC?

 

Sorry but I am not sure about that

 

If you were to put a evc on your 12 t turbo, the 2001 turbo for the v40, think you would still need to do a ecu ! ? Tune, can't seem to find a place to do it, idp says they can't so anything for v40 ...

 

You could always go rising rate fuel pressure regulator. It will not do anything for timing but will get you more fuel flow to match more boost.

 

The stock Turbo on all USA spec 40s Is The MHI TD04L 12T turbo with a stock boost pressure of 7.5 psi After 90,000 miles a rebuild is recommended There are some great rebuild kits for around 50$ that have upgraded piston rings and forged thrust collars and surface with dual oil ports. And if you want more power mamba tek make a killer stage 3 rebuild upgrade kit for the 12T t and 14T for around 300$. It includes same rings and collars and plate but also includes a extended tip billet compressor wheel and lightweight high flow 9 blade turbine that gas blades twice the size of stock 12 blade. It flows 15% more air in and 35% more air out giving a huge increase in power and topend and dropping the egt ebp. It is very easy to upgrade to the 14t as well. Im running the mamba kit on my 14T. 2001 V40

 

Never heard of mambatek until now. Good reference site! They sell a 14T from the S40 T4 design new for $369! Put that in plus a tune and you'd be in the 200+ HP range with a very reliable design - that's on par with the VW/Audi 2.0Ts.

 

Olá . Esse kit mamba 9-6 estagio 3 é de aplicação directa e sem ter de usinar, desbastar a tampa da compressora certo?
O carro fica com um bom upgrade em relação a 1 tdo4l stock?
Obrigada

 

I put my Mityvac on the turbo vacuum actuator this afternoon and the actuator did not move. So I'm looking for a new actuator. Do you have any ideas? Thanks!