Part Focus: Turbos / Brands: BTN
SES Autoparts get together with SCM to provide common trouble shooting advice and fitting tips for turbos.
Loss of power, excess smoke, high fuel consumption, overheating, high exhaust temperatures and oil leakages from the turbocharger are all symptoms that could indicate turbocharger malfunction. However, these faults are often wrongly attributed to the turbocharger because defects in other components can produce the same symptoms. The turbocharger performance can only be impaired by mechanical damage or blockage caused by dirt.
This checklist provides a comprehensive list of the most common symptoms related to turbocharger failure. BEFORE replacing a turbocharger, verify the problem by consulting the chart over. other components can produce the same symptoms. The turbocharger performance can only be impaired by mechanical damage or blockage caused by dirt.
PREPERATION
Identify the issue that cause the previous turbo charger to fail, and rectify the issue before installing the replacement unit (see fault diagnoses chart overleaf for assistance.
Ensure the faces/flange of the oil pipe are clean. We strongly recommend replacing the oil feed and drain pipe when replacing the turbo.
Check the manifold faces and flanges are clean and free from damage.
Ensure the intercooler and air intake system are clean and free of debris.
Always check the engine breather pipes for blockages and restrictions.
Keep the work area free from dirt and other particles. Even the tiniest bit of contamination can cause the turbo to fail shortly after fitting.
FITTING / PRIMING
Before fitting the turbocharger fill the turbochargers oil feed hole with oil and rotate the rotor by hand.
Replace the oil filter and prime it with the manufacturer’s recommended oil, then fill the engine with oil.
Fit the turbocharger to the vehicle leaving the air intake and oil pipes disconnected. Disconnect the ignition or fuel supply so the engine will crank over without starting.
Connect the oil feed pip to the engine only, and the crank the engine over until oil can be seen flowing strongly out of the oil feed pipe.
Connect the oil feed pipe to the turbocharger.
Attach the oil return pipe to the turbocharger using the correct gasket. Do not use liquid sealant, use of this will void the warranty.
Crank the engine over again (still without firing) so a good flow of oil can be seen flowing freely out of the oil return pipe. This ensures all air pockets are removed from the oil system.
Connect the oil return pipe to the engine, and reconnect all remaining hoses (air intake, intercooler etc). Crank the engine over again until the oil pressure warning light goes out.
Reconnect the ignition system of fuel supply, the engine is now ready to start.
Once started leave the engine to idle for five minutes, checking the turbocharger for any oil, air or exhaust leaks. Soapy water can be sprayed over the air connections to look for leakages.
Do not leave the engine to idle for more than five minutes as this could cause oil to access the exhaust system, resulting in smoke from the exhaust.
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