1. 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. 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. 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. 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. 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.

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. 1. Engine Lacks Power

   • • Worn internal engine components
   • • Low Boost
   • • Air filter/pipe blocked
   • • Air pipe leaking from filter to turbo

2. 2. Turbo Noisy

   • • Air leak – exhaust gases leaking from manifold or pipes
   • • Air filter/pipe blocked
   • • Air pipe leaking from filter to turbo

3. 3. Exhaust Smoke

   • • Check intercooler
   • • Check head gasket
   • • Check turbo internal components
   • • Insufficient oil supply to turbocharger
   • • Actuator arm stuck in overboost

4. 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. 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.