The Topic:
This DIY will guide you through the bearing swap on a TE05-12B turbo.

The Problem:
When you you check the turbo axis for clearance and you feel a "large" gap (more than 0.5 mm) when moving the axis up and down. Then you need might need to change the bearings. Or if the turbo pushes oil into the turbine (blue smoke when at max boost), then you need to exchange the oil-ring on the turbine axis.

When doing his operation you need to use:
- Real tools (no monkey wrenches, and other creative tools)
- Same kind of engine oil that use in the car for cleaning and lubrication of the turbo
- Never use sanding equipment to clean any interior or moving parts of the turbo

REMEMBER!
The turbo is a balanced high performance compressor driven by a turbine mounted on the same axis. This axis must be balanced! 
So don't do anything that you know will affect the balancing of the turbo

Another problem is to find the spare parts for the turbo.
Visit Melett (www.melett.com), a great company supplying the turbo parts you need.
I recommend them strongly!

They also sells a "repair-kits" for different turbo's, these kits include all the parts you need to rebuild the turbo. I only needed to change the bearings, but if your not certain of what's worn on your turbo, buy the kit!

The Solution:
This is going to be a "step by step" DIY. So lets start...

  1. Let the car cool and remove the bonnet.

  2. Remove the + battery connector

  3. Remove the hoses to and from the turbo's compressor side

  4. Drain the water from the engine

  5. Dismantle all water and oil lines to and from the turbo.

  6. Separate the turbo body from the exhaust house by loosening the clamp holding the turbo body and exhaust house together

  7. Separate the compressor housing from the turbo body.

    Compressor housing and turbo body separated

  8. Mark the compressor wheels position on the turbine axis. IMPORTANT! must be done or the balance is off. The turbo won't work perfectly and the the new bearings will worn out rather quick.

    Compressor wheel and axis marked for position.

  9. Remove the compressor wheel nut and remove the compressor, IMPORTANT! use a socket on the turbine axis nut to lock the axis.

    Compressor wheel removed

  10. Remove the "snap ring" and remove the insert with the oil deflector.

    Insert and oil deflector removed

  11. Remove the O-ring, thrust ring, and the thrust bearing.

    Compressor side bearing showing

  12. Tip the turbo and the bearing "slides" out.

  13. Compressor side parts laid out 
    from the left to right:
    Top row:
    nut, compressor, snap ring, insert, oil deflector
    Middle row:
    O-ring, thrust ring, thrust bearing, bearing
    Bottom row:
    new bearings

    Parts on paper

  14. Press out the turbine axis.

    Turbine axis showing the bearing

  15. Now you got the turbo in pieces.

    Turbine axis with bearing and the turbine piston ring on the axis

  16. Lift of the heat shield.

    Heat shield off

  17. All the parts laid out.

    Parts on paper 2

  18. Time to clean everything, use a cloth and fresh motor oil. Use a hard plastic knife or soft metal knife to carefully scrape off all carbonised oil. But you must not make any scratches at all on any part.

  19. Check the turbine axis for wear and tear. If the axis shows major damage then you need to send the turbo to a specialist. But if it shows marks like this axis, then just the bearings were needed to be changed.

    If the turbo pushes oil into the exhaust house during high boost then the piston ring on the axis is needed to be exchanged.

    Cleaned axis with piston ring mounted

  20. Inspect the bearings and exchange them.

    New bearings in the middle 
    Compressor bearing on the left
    Turbine bearing on the right 

  21. From now on every internal part shall be oiled before mounting.

  22. Mount bearing on the turbine axis. Mount the axis in the turbo body.

    Inserting the turbine axis

  23. Mount the compressor bearing.

    Well oiled bearing about to be "slotted" in

  24. Mount the thrust bearing.

    Thrust bearing sliding down the axis 

  25. Mount the thrust ring and the o-ring.

    O-ring about to be mounted

  26. Put the oil deflector together with the insert.
    If the turbo pushes oil into the compressor side during high boost, exchange the piston ring on the central part of the oil deflector.

    Oil deflector inserted in the insert 

  27. Slide the insert on the axis. Press the insert into the turbo body.

    "
    Slide on"

  28. Lock the insert in the turbo body with the snap ring.

    "locked!"

  29. Mount the compressor wheel and the nut. Align the "marks".

    Note the "marks"

  30. Tighten the nut on the axis to lock the compressor wheel. 
    The compressor wheel will follow the nut around when tension is added, so be careful of the "marks". You shall not force the compressor wheel to stay in one place due to the risk of deformation and rupturing. Just turn the compressor wheel a little bit before tensioning the nut.

    Compressor wheel locked on target

  31. Mount the compressor housing

    Turbo put together

  32. Put everything back in reverse order (hoses, IC, etc.). But remember to fill the turbo with fresh oil before tightening the oil line to the turbo.

  33. Fill up the coolant

  34. put back the battery connector, mount the bonnet.
     

  35. Done!