Replacement of the Turbocharger fitted in VW Engine

SUBJECT: Fitting advice

The turbochargers generally fails as a result of an incorrect oil supply. This is due to the fact that the oil inlet pipe is easily blocked, having a very small bore and 90º angles. The oil gradually solidifies inside the pipe, blocking the oil inlet and finally causing the shaft to seize up. It frequently happens that, on shaft seizure, the screw thread shoots out and damages the inlet turbine.

Whenever the turbocharger is replaced, we would recommend replacing the oil inlet pipe. If this is not done, the pipe should be thoroughly cleaned and inspected for blockages.

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Replacement of Turbocharger With Ref. 708639-703245…..

Pay particular attention when mounting this turbo on the engine, as the seal between the turbo and the exhaust downpipe can be mounted in two different ways, and only one is correct.

As can be seen in the photos below, there is only one way to correctly seat the seal. If incorrectly seated, the exhaust gas inlet to the turbo exhaust is partly blocked and the turbo will not operate correctly.

Incorrect fitment could result in turbocharger failure.

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Replacement of the BMW 320D Turbo

n the majority of cases turbochargers mounted on the BMW 320D – engine M47TU fail due to a fault in the car exhaust gas re-circulation system.

Whenever the turbo is replaced, the filter located in this system must be checked. This problem has already been corrected by the manufacturer in the new BMW 320D models.

For those models with the old filter (C), this must be replaced with BMW kit (D) (11127799224) which is designed to prevent the problem from reoccurring.

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PSA 1.6 Hdi Turbocharger Failure & Fitting Warning

753420-ANY & 49173-07508 5435-0988-0009 110/90/75 HP PSA 1.6 HDi TURBOS, 2004- ONWARDS


The PSA 1.6HDi, DV6TED4 engine is a highly sophisticated low emission, high power diesel unit. It is used in many different applications Citroen, Ford, Mazda, Mini, Peugeot and Volvo.
Due to the engine being clean and powerful, it is designed to operate with high temperatures, which demands the very best lubricants. These lubricants must be maintained in peak condition and PSA have fitted an in-line oil filter to the turbo and an integral oil cooler/oil filter to this engine to ensure this. However there is a drawback to this, reports from in the field indicates that if the engine has been operated with the oil level below normal limits, this may potentially cause a high concentration of carbon in the oil. This may then lead to blockage of the in-line filter, oil cooler and main oil filter, which will eventually bring on premature turbo failure. The vacuum pump may also suffer from this same type of contamination. However, due to its high operating speeds (230,000 revs per minute) the turbo will usually be the first to show signs of damage. This can happen from 30,000 miles onwards if the oil level and correct oil change intervals/procedure have not been adhered to. Continue Reading

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Identifying a Faulty Diesel Advance Actuator Solenoid

SUBJECT: Faulty Actuators can cause several problems on the vehicle.

The Advance actuator solenoid generally fails as a result of contamination within the fuel system. This will often cause the following symptoms.

  • Hesitations when accelerating under load at approximately 2,000 rpm
  • Poor cold start
  • Unstable idle
  • Rushing noise for the first few seconds after starting the engine
  • Unstable engine and smoke accompanied by engine noise and a lack of power when the engine is cold

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Faulty DRV

Common Rail Pressure Regulator

A Common Rail Pressure Regulator is a type of solenoid valve. UK Diesel Parts Common Rail Pressure Regulator Valve also know in the industry as Diesel Regulator Valve (DRV) or Fuel Pressure Regulator (FPR) are fixed to the common rail high-pressure pumps or to the common rail in majority of modern diesel cars.

The function of the Common Rail Pressure Regulator is to keep the pressure in the rail at a constant level. Common rail pressure sensor indicators the pressure required in the fuel rail to the ECU.

The ECU then switches the regulator to open or close. The rail encompasses a pressurised quantity of diesel fuel ready for the injectors to use, when the pressure in the rail drops the sensor signals this to the ECU and pressure is replenished.

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Identifying Turbocharger Problems

Turbochargers are rotating machines that operate at high speeds and temperatures. The most common causes of turbo failure are:

  • Lubrication related problems
  • Ingress of foreign material
  • Extreme operating temperature
  • Workmanship problems/Incorrect fitment

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Reading your Turbocharger

Understand and identifying nameplate meaning.

Getting the correct model for your vehicle is very important so ensure you identify which model is fitted to your vehicle we have a guide explaining the nameplate characters.

The turbo model says a great deal about the features of your turbocharger.

For example, in the T Series, turbo model TO4B59 is formed as follows:

  • TO4 = frame size (74.2mm turbine);
  • B = the design;
  • 59 = the 59th TO4B that we made, usually specific to one customer.

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What causes an EGR valve to fail?

What is an EGR Valve?

The Exhaust Gas Recirculation Valve, or more commonly known as the (EGR) valve, controls the engines emission of nitrous oxidize or Nox. It helps your vehicles to efficiently burn unused fuel by recirculating a portion of your exhaust through the process again. This then reduces the amount of harmful gases your vehicle would produce.

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Why does an Air Mass Sensor Fail?

There are lot of possible reasons for a Air Mass Sensor to fail.

The Air Mass Sensor, also known as Mass Airflow Sensor, Air Mass Meter, Mass Airflow Meter, MAF or AFM essentially measures the amount of air that passes through to the engine to create an air / fuel ratio that allows your car to reach its full potential and efficiency. The sensor on MAF device is very sensitive and can be easily contaminated by dirt, debris and oil. This fault may not then show up on your diagnostic system as your cars computer may think the device is still working within its limit which it considers to be ok. This then means that there may be a lack of power, high fuel consumption, poor starting and stalling. Continue Reading

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