Hi there,
Good news for me today ! My D5 engine doesn't go into limp mode anymore, it's fixed ! It pulls as it should, reaches 5000 rpm, kickdown are strong, bref, it works !
I had time today, so I decided to remove the turbo from the engine, put it on the bench and dismantle it.
Here are some photos I took to show how I proceeded and that it's a pretty easy task apart from the soot I can't get rid off my fingers...
The beast
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Remove the clip
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Remove the 3 bolts that hold the actuator, remove it and undo the 4 remaining bolts
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Now take a soft hammer and gently tap on the body, it comes easily, don't be shy on the use of WD40
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Aaah ! there we are ! What's inside....?
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As you will see in the video, the vanes are stuck and in need of a thorough cleaning... Undo the 3 screws
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Pull the "vanes carrier" off of the body...
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Be careful not to lose the sleeves...
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Clean every parts, brush them, soak them in WD40 or something more corosive, anything that can remove the soot and leave your parts spotless and crystal clear ! Ultrasonic cleaning would have been my best bet but I had no time to find and go to a company that supply this service... So parts are cleaned and back in place, the ring and plate are moving freely, smoothly, at this moment I felt pretty confident.
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With the turbo almost "new" I reinstalled it on the engine, changed the gaskets, seals, nuts and started the engine my left hand touching wood and my right hand fingers crossed. It's 10pm, dark outside, I finished working under the car with a torch light for only light exactly what not to do... had a last check, no leaks, no weird sounds, no smoke, no fire, ok I went for a test drive... It sounds good the transmission shifts as it did in the past (when the car used to work), engine runs smooth. I accelerate to 2500 rpm, no problem, let's try 3000 rpm, no problem, good ! It's WOT time, unthinkable this morning, limp mode past 2400 for sure !!! And here we go 2500-3000-3500-4500-redline, fantastic...! Power is back, torque is back, my leadfoot is back !
I will do some vacuum tests tomorow with the gauge just to confirm that everything is fine.
The videos are uploading at the moment, I will post them tomorrow...