Expert Turbocharger and Turbo Kit Sales and Repairs in Harare, Zimbabwe.

FAQ

SUPPLIERS OF ALL TYPES OF BRAND NEW QUALIT TURBO CHARGERS

Benefits of Regular Filter Maintenance

Regular filter maintenance is the key to a healthy turbine charger system, offering a host of benefits that keep your engine purring like a well-oiled machine.

Extended Lifespan of Turbine Charger System

By changing filters regularly, you can prolong the life of your turbine charger system, avoiding costly repairs and replacements down the road.

2. Improved Efficiency and Performance

Clean filters promote optimal airflow and fuel delivery, leading to improved efficiency, better performance, and a smoother driving experience. It’s like giving your engine a spa day, but without the cucumbers.### Common Issues Caused by Filter Neglect

3. Contamination of Turbine Components
When filters are neglected, dirt, debris, and contaminants can bypass the filter and enter the turbine system. This can lead to increased wear and tear on turbine components, affecting their performance and lifespan.

4. Reduced System Efficiency
Dirty filters can restrict airflow, causing the turbine system to work harder to maintain optimal performance. This can result in reduced efficiency, higher energy consumption, and potential damage to the system over time.

FAQ

Frequency Asked Question

TURBO Installation Instructions: General

Step 1: Before Replacing A Turbo

It is important to conduct a thorough diagnostic check of the engine system to determine if the “fault” is actually the turbocharger.

A lack of power, noisy operation, excessive smoke or oil consumption could result from a faulty fuel injection system, ECU or electrical problems, restricted or blocked air filter, a damaged exhaust system or a lubrication problem. If possible, check crankcase pressure according to the engine manufacturer’s specification. A higher than normal crankcase pressure reading may lead to oil leakage from the turbo into the inlet and exhaust systems.

Step 2: Before Replacing A Turbo

If the engine diagnostic check does not uncover any obvious cause,

make sure that an extensive trouble shooting analysis is completed. Key turbocharger areas for examination include foreign objects, lack of lubrication, oil contamination, over-speeding of the turbo and excessive temperature. This is important because turbo damage can often be a symptom of an underlying problem rather than the cause itself. Our website has more detailed information on this subject – please click here to learn more.

The following steps must be strictly followed.

Always consult the workshop manual for instructions which are specific to your engine or vehicle.

Step 3: Turbo Installation

Check the part number to ensure that it is the right one for the engine.

Installing the incorrect turbo to an engine may damage the turbo and/or the engine and will void the warranty.

Step 4: Turbo Installation

It is important that during the whole installation process, you prevent dirt or debris from entering any part of the turbo.

Any dirt or debris entering the turbo may cause catastrophic damage due to the very high speed of operation (up to 300,000rpm).

Step 5: Turbo Installation

Ensure that correct gaskets are used.

For example – the center hole of any gasket must be perfectly aligned with the center hole of the turbo flange. Some turbos use a threaded connector and no gasket. Some turbos use a “banjo fitting” with “banjo bolt”; in these cases, use new sealing gaskets/washers.

Important Note: Do not use liquid gasket or sealants, particularly for the oil inlet or outlet since excessive material may enter the turbo, reducing or stopping oil flow.

Step 6: Turbo Installation

It is recommended that you use new air, oil and fuel filters and clean engine oil to the engine or vehicle maker’s specification.

When installing the new oil filter, if possible, fill it with clean, fresh engine oil. Also, if it is accessible, back-fill the pressure line from the oil pump to the filter. This is particularly important on high mileage engines, where the oil pressure line may empty during oil changes!

Step 7: Turbo Installation

Before installing the turbo, ensure that all air hoses connected to the turbo are totally clean and show no sign of any damage.

Step 8: Turbo Installation

The air filter and its housing must be completely clean and free from any debris.

Step 9: Turbo Installation

Clean the engine breather system (Positive Crankcase Ventilation system) and ensure that it functions properly.

Any blockages or malfunction may cause high crankcase pressure and lead to oil leakage from the turbo into the inlet and exhaust systems.

Step 10: Turbo Installation

Remove any old gasket material from the exhaust manifold and pipe.

The surfaces of the flange must be clean and have no damage. Then remove plastic or foam blanking plugs from the turbo.

How to install a new Turbo

Step 11: Turbo Installation

Position the turbo onto manifold or engine block using the correct new gasket or O ring, and then reconnect the exhaust pipe.

Tighten all nuts and bolts.

Important Note for Steps 12-15 Pay special attention to oil feed and drain lines, which must be totally clean and have no damage to ensure unrestricted oil flow. Make sure that flexible hose liners have not collapsed internally and that the oil feed line is not too close to source of heat which may have damaged the oil feed line internally. This is common on some vehicles and difficult to detect without cutting the pipe! For this reason, we recommend fitting a new oil inlet pipe when installing the new turbo.

Step 12: Turbo Installation

Next, install oil drain line to the turbocharger.

Step 13: Turbo Installation

Pour new engine oil into the oil inlet hole of the turbocharger.

Step 14: Turbo Installation

Next, fit the new oil feed line.

Step 15: Turbo Installation

Install inlet and outlet air hoses to turbocharger compressor housing.

Make sure that the connections are airtight and hose clamps are correctly tightened.*

Step 16: Turbo Installation

Crank the engine for 10 – 15 seconds without starting the engine.

If possible, disable the fuelling/ignition or use compression test mode to allow this. This helps to prime the oil feed to the turbocharger by filling the oil pressure lines, oil filter and turbo with oil before start-up. Important Note: As soon as the engine starts, the turbo will run at high speed and a lack of lubrication in these vital first few seconds can destroy a brand new turbo.

Step 17: Turbo Installation

Then start the engine, and let it idle for 3 to 4 minutes to allow for proper inspection of oil, gas and air leakage.

If any leakage is detected during engine start up, fix the issue immediately.

Step 18: Turbo Installation

Stop the engine and re-check engine oil level.

Oil level should be between the minimum and maximum mark on the dipstick – it is important to make sure that oil level is not above the point where turbo oil drain pipe connects to the engine or this may lead to oil leakage from the turbo into the inlet and exhaust systems.

How to identify a turbo and electronic actuator?

Ideally, we also need the turbo part number. The location of this turbo part number, on the turbo as a component, can vary, by turbo/vehicle manufacturer/vehicle marque. To assist you in having this information, readily available, when you call our technical sales staff, we identify below, by turbo manufacturer, where this part number can be found on the turbo component.

To ensure we supply you with the correct turbo, please supply the following details:

It is preferable if you can supply us with the make and part number of the actual turbo fitted to your car (See below for general guidance). If after following the guide you cannot find these details, your main dealer may be able to assist you.

Failing that, we will probably be able to identify the type of turbo you require from the make and model of your car and your registration number. We will need to know:

• Make, eg Audi

• Model, eg A4

• Chassis Number

• Registration number / date of manufacture /model year eg. 2008

• Size of engine, eg 2-litre

Why Turbos Fail?

Complete a diagnostic check before you replace your turbo

LACK OF POWER

-Check that filter, hoses and pipes are clean and in good condition
-Check that the fuel injection system is in good condition and correctly adjusted
-Check that the exhaust system, including catalyst and DPF, is not blocked or damaged

NOISY PERFORMANCE

-Check that the pipework and support brackets are not loose or damaged and that the connections are good
-Check for any leakages or cracks in the intercooler

EXCESSIVE SMOKE OR OIL CONSUMPTION

-Check that air filters are not restricted or blocked
-Check that engine oil specifications strictly correspond to car manufacturer’s recommendations
-Check that the oil drain pipe is clean and not restricted
-Check for excessive pressure in engine crankcase and correct function of engine breather system
-Check that hoses and joints are in good condition
-Check for lubrication problems in engine block if oil or carbon deposits are found on exhaust manifolds or in the turbine

The Turbo Specialist Diagnostic

If there is no obvious cause, make sure your turbo specialist completes an extensive troubleshooting program. The causes for turbo damages usually fall into the following four categories:

1. Foreign Objects

Turbo wheel damage, caused by small objects entering the turbine or compressor housing at high speed, leading to imbalance.

2. Lack of lubrication

Turbo fatigue cracking and material transfer created by metal friction and high temperatures as a result of oil inlet supply restrictions, incorrect gasket placement and use of liquid gaskets or poor quality lubricants.

3. Oil Contamination

Turbo bearing system damage caused by a high concentration of carbon suspended in oil, created by extended oil change intervals or poor maintenance. Bearing damage caused by a steel shot suspended in oil following a major engine overhaul.

4. Overspeed & Excessive Temperature

Turbo damage caused by working beyond its designed parameters or outside the vehicle manufacturer’s specification. Maintenance problems, engine malfunction or unauthorized performance upgrades can push turbo rotating speeds beyond its operating limits, causing fatigue failure or compressor and turbine wheels.

Types of Filters Used in Turbine Charger Systems

In the world of turbine charger systems, there are three main types of filters that keep everything running smoothly:

1. Air Filters

Air filters shield the system from dust, dirt, and debris, ensuring only clean air enters the combustion chamber for efficient engine operation.

2. Fuel Filters

Fuel filters act as gatekeepers, preventing contaminants from clogging fuel injectors and causing engine misfires or reduced performance.

3. Oil Filters

Oil filters keep the engine well-lubricated by trapping impurities that can cause friction and wear, extending the life of the turbine charger system.
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Importance of Filters in Turbine Charger Systems

Filters in turbine charger systems play a crucial role in keeping the system healthy and happy. They act as the first line of defense, trapping dirt and debris before they wreak havoc on your engine.

* Function of Filters in Turbine Charger Systems

Filters are the unsung heroes that prevent harmful particles from entering the system and causing damage. They ensure only clean air, fuel, and oil make their way into the turbine charger system, maintaining its efficiency and longevity.

* Impact of Clean Filters on System Performance

Clean filters are like a breath of fresh air for your turbine charger system. They allow optimal airflow, prevent contamination, and help the system perform at its best, maximizing power output and fuel efficiency.