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Fitting Guide

Before you fit a new turbo, you may want to investigate the cause of the original’s failure. Most turbo failures are due to:

  • Oil Starvation/Contamination
  • Electronic Sensors
  • Air Leaks Leading to Overspeeding
  • Foreign Matter Entering Compressor Housing
  • Breather Problems
  • Incorrect Turbo Installed

Rectify the Malfunction

Upon completion of diagnosis and conclusion of malfunction or component failure, you must either rectify the malfunction or replace the failed components with new fittings. Make sure that you retain proof of purchase, including receipts and check for foreign particles all before you fit the new turbo.

Replace the Components

Before fitting your new/remanufactured turbo, you must replace components listed below with new components and again, retain all receipts:

  • 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 (Peugeot™/Citroen™/Ford™/Mazda™/Volvo™ 1.6 Diesel)
  • Oil and Oil Filter (Correct Grade as per Manufacturers’ Recommendation)
  • Air Filter
  • Gaskets and Washers, O-Rings
  • DPF (Diesel Particulate Filter) Liquid Level
  • Sensor Topped up with Fluid Level

Clean or replace your turbo

  • 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), Ensure Pressure is Tested
  • EGR 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

Install and Test Your Turbo

  • Check Oil Pressure is Within Manufacturers’ Tolerances
  • Do Not Use Jointing Compound on Any Part of the Turbo
  • Before Fitting, Fill Turbo Inlet with Oil and Prime Turbo Manually
  • Before Fitting Turbo, Immobilise Engine (for Example, Remove Fuel Pump Fuse) Manually Crank Engine until Oil Flows Steadily out of Turbo Oil Feed Hose
  • After Fitting Turbo, Manually Crank Engine for 30 Sec until Oil Flows from Turbo Oil Return Pipe
  • Start Engine and Allow to Idle for 3 to 5 Minutes 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), Check Boost Pressure
  • Must Get Diagnostic Retest Done After 50 to 60 Miles and Replace Any Item That Reappears in Diagnosis © 2018

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