Technical Know-How
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.
Causes Of Failure
Distributor Pumps
Common Rail Systems
Turbochargers
Distributor Pumps
Causes Of Failure
Physical Damage
Improper Torque , Improper Or Faulty Pump Gear
Causes Of Failure
Adulterated Fuel
Bio Diesel , Poor, Abrasive Fuel (Particles) , Poor, Inadequate Filtration
Engine Oil In Fuel System , Incorrect Or Non-approved Additives
Causes Of Failure
Adulterated Fuel , Water In Fuel
Water In fuel , Heavy Rusting , Poor, Abrasive Fuel (Particles) , Poor, Inadequate Filtration , Incorrect Or Non-approved Additives
Causes Of Failure
Low Lubricity
Poor, Inadequate Filtration , Low Inlet Pressure or Negative Pressure In Fuel Line
Causes Of Failure
Incorrect Timing Lock
Over Tightening Of Timing Bolt , Heat Generation , Leakage From Shaft
Common Rail Systems
Causes Of Failure
Combustion Residue Out Side Of Injectors
Injector incorrectly installed (tightened or twisted on one side) , No sealing ring , Inadequate tightening torque when installed
Causes Of Failure
Thermal Overload Or Injection Bore Burnt
Diesel Tuning , Incorrect Or Non-approved Additives In Fuel , Engine Oil In Intake System , Oil Thinning , Biodiesel
Causes Of Failure
Nozzle Tip Melted Or Burnt
Diesel tuning , Incorrect or non-approved additives in fuel , Engine oil in intake system , Oil thinning , Biodiesel , Aluminum Deposits In Nozzle Shaft
Causes Of Failure
Foreign Particle In Combustion Chamber
Mechanical Damage To The Nozzle
Causes Of Failure
Particles In Fuel Or Fuel Adulteration
Poor, Abrasive Fuel (Particles) , Poor, Inadequate Filtration
Causes Of Failure
Poor Or Adulterated Fuel Or Water In Fuel
Engine Oil In Fuel System , Incorrect Or Non-approved Additives In Fuel Or Water In Fuel , Inadequate Filtration, Poor Filter Quality Or Filter Service Life Exceeded
Causes Of Failure
Oil Deposits In Interior
Engine Oil In Fuel System , Leak In Engine Oil Lubricated CP , Leak On Fuel Return Side Of Cylinder Head (CRIN)
Causes Of Failure
Electrical Failure
Short Circuit Sensors , Engine Oil In Fuel System , Incorrect Or Non-approved Additives In Fuel Or Water In Fuel
Causes Of Failure
Foreign Objects
Turbo Wheel Damage, Caused By Small Objects Entering The Turbine Or Compressor Housing At High Speed, Leading To Imbalance.
Damage To A Compressor Wheel
Damage To Nozzle Ring Assembly
Damage To A Compressor Wheel
Causes Of Failure
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 Or Immediate Acceleration On Idle On Ignition.
Incorrect Shape And Position Of Gasket
High Temperature And Material Transfer From Bearing
Causes Of Failure
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.
Worn And Scored Bearing. Material Transfer To The Shaft
Large Particles In Oil Can Cause Deep Scoring And Impacts
Worn And Scored Bearing. Material Transfer To The Shaft
Causes Of Failure
Overspeed & Excessive Temperature
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.
Orange Peel Effect On Back Face Of Compressor Wheel Is A Clear Sign Of Over Speeding
Causes Of Failure
Large Particles Can Cause Deep Scoring And Impacts
Engine Back Compression
Oil From Exhaust Causes Shaft To Imbalance Thus Causing Play At High Speeds Leading To Damaging Of The Turbo Chargers
