• Installation/Fitting Tips
• 1.Why turbos fail? – Diagnosis
  
  Investigate cause of original turbo failure before fitting replacement
  Most turbo failures are due to – Oil Starvation/Contamination, Electronics sensors, Air leaks over speeding turbo, or foreign matter entering compressor housing. Breather problems.
  
  2.Rectify Malfunction
  
  Upon completion of diagnosis and conclusion of malfunction or component failure, either you must rectify the malfunction or replace the failed components with new components. Check for foreign particles. All BEFORE you fit the new turbo.
  
  3.Replace Components
  
  Before fitting your new Turbo, you must Replace Components listed below
  OIL FEED PIPE (from engine to top of turbo), replace banjo bolts and oil drain
  Replace Turbo oil drain hose (check clear / check no damage to pipe)
  NEW OIL PUMP
  Oil and oil filter (correct grade as per manufacturers recommendation)
  Air filter
  Gaskets and washers, O rings
  Diesel Particulate Filter liquid level sensor topped up with fluid level
  
  4.Clean or Replace
  
  Diesel Injectors – Clean, Test, Replace
  Air box and air intake hose to turbo (Pressure Test)
  Oil cooler/ intercooler/ hose, from turbo to intercooler (damage or air leak). Get Pressure Tested
  E.G.R VALVE – Check correct operation, clean or replace if necessary
  Breather system, cam cover (rocker cover) – check for blockage
  Clean Inlet/exhaust manifolds, check for carbon deposits/cracks/clean head faces/replace gaskets
  Ensure the exhaust and/or catalytic converter/diesel particulate filter (DPF) are not fully or partly blocked
  Before fitting Turbo – check no debris enters turbo, check all gaskets fit with gas tight seal
  Flush Engine
  
  5.Fit and Test Turbo
  
  Check OIL PRESSURE is within manufacturers Tolerances
  Start engine and allow to idle for 3-5 mins before driving (do not let engine idle unnecessarily)
  Check for Oil/Gasket/Air Leaks, All OBVIOUS locations on engine
  Plug into diagnostic machine to check for any fault codes (rectify or repair as per diagnosis, before road test).
  
  A professional mechanic or turbo tuning shop is only recommended for the turbo fitting job of your car. The external influence on the failure of the turbo is not included in the warranty. And only with the turbo properly fitted, you will have your car return to the road earlier.
  
  

• Troubles shooting
• Turbochargers are very reliable: only 1% of turbo failures are due to bad manufacturing or manufacturing errors and therefore problems relating to the engine are far more common causes for turbo failures. Before removing your turbocharger from the vehicle, please check try one of these recommended remedies
  
  1.Engine Lacks Power
  Worn internal engine components
  Low Boost
  Air filter/pipe blocked
  Air pipe leaking from filter to turbo
  2.Turbo Noisy
  Air leak – exhaust gases leaking from manifold or pipes
  Air filter/pipe blocked
  Air pipe leaking from filter to turbo
  3.Exhaust Smoke
  Check intercooler
  Check head gasket
  Check turbo internal components
  Insufficient oil supply to turbocharger
  Actuator arm stuck in overboost
  4.Boost pressure too high
  Boost pressure control valve is closed- Hoses split or incorrectly fitted
  Check fuel system
  Wastegate activator diaphragm split or incorrectly fitted
  Check fuel system
  5.Excessive Engine Oil Consumption
  Fuel system defective
  Replace or adjust faulty components
  Check Air pipe from turbo to inlet manifold
  Check hoses and intercooler for leaks and replace
  Incorrect operation of crankcase breather system
  Check breather hoses, pipes and one way valves breather system
  
  More often than not a defective turbocharger is the consequence of some other primary engine defect which cannot be cured just by replacing the turbocharger. Before you fit a new turbo, find out what caused the first unit to fail or you risk the replacement failing too.
  

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