Correct installation is the key to ensuring your repaired/rebuild/ new units doesn't give problems in the future.
First things first, why did the original unit unit fail? Did you know that over 90% of failures are caused due to outside influence? This can be oil contamination, oil starvation, foreign object damage, as well as fuel contamination , fuel delay or starvation. Before fitting a repaired/rebuild/ new unit, you MUST find the cause of the original failure and correct it before fitting the repaired/rebuild/ new unit.
Common Rail Systems
•Diagnose And Solve The Reason For The Failure Of The Old Turbocharger (Possibly A Fault On Or Around Engine).
•Compare Turbocharger Model Number With The Engine Specifications And The Turbocharger Manufacturer’s Model Number.
•Sump Must Be Removed And Cleaned.
•Oil Strainer Must Be Removed And Replaced Due To Residual Carbon/Sludge Build-up.
•Oil Pump Should Be Removed And Checked.
•Oil Cooler And Filter Assembly Should Be Removed And Cleaned.
•Check For Proper Engine Cooling.
•Check Oil Supply, Make Sure Oil Return From The Turbocharger To The Crankcase Is Clear.
•Intake, Charge Air And Exhaust Area:- Check For Functional Capability , Clean Out Any Contamination By Foreign Bodies Or Fluids And Solve Why They Were Present And Clean Any Undamaged Air Supply Hoses And Pipes.
•In The Case Of Liquid-cooled Turbochargers: Check For Adequate Coolant Flow.
•Check Whether An Adjustment Of The Housing Position Is Necessary.
•Torque Fasteners As Specified By The Engine And Vehicle Manufacturer.
•Make Sure The Flanges And Threads Are Free Of Damage, Debris And Wear.
•Use Only Brand New Gaskets And Seals.
•Exhaust System To Be Checked For Contamination/Blockage (Catalyst, DPF Etc.).
•Turbocharger Oil Feed Pipe & Banjo Bolts Must Be Replaced.
•New Oil Filter And Oil To Be Fitted.
New Air Filter To Be Fitted.
•Before Securing The Oil Supply Line The Turbocharger Should Be Filled With New Engine Oil Through The Oil Inlet Hole, While Slightly Turning The Rotor Manually.
•Attention Paid To Correct Handling.
•Oil Flow Must Be Checked:
– Fit Turbocharger To Engine Leaving Oil Return Pipe Off.
– Install A Longer Oil Return Line And Feed Into Suitable Container.
– Start Engine And Idle For 60 Seconds, Then Switch Off Engine.
– Measure Volume Of Oil In Container – 60 Seconds Of Idle Should Produce At Least 0.3 Liters Of Oil.
– Repeat Test Two Or Three Times To Confirm Oil Flow Is Correct.
– During This Test, Do Not Allow Engine To Run Below Minimum Oil Level!
•Idle For Approximately 120 Seconds After Engine Is Running.
•During Idling: All Connections (Air, Exhaust, Water And Oil) Checked For Firm Seating, Tightness And Free Of Leaks, Gas-tightness Checked With Soapy Water If Necessary