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Technology information

The most common causes of damage to the turbocharger

1.Contamination of oil

-for low- quality oil filter , damaged or clogged

-the loss of the oil attribute as a result of moisture oil

-oil carbon deposits in the engine that cause oil contamination

-oil pollution caused by the wear of engine components e.g. socket


2.Overspeeding- excessive speed

-engine modification ” chips ” or ” over- fueling ” excessive fuel supply

– variable air flow to the turbocharger

– worn injectors

– loss of signal to the electronic actuator driver wastegate or variable geometry controller

3.Lack of lubrication improper lubrication

– low oil level in the sump

– limit the intake of oil to the turbocharger by the incorrect installation of the seal

– damaged oil filter or the low quality


4.Damage caused by foreign body

– sucked object by a defective / faulty or poor quality air filter

– sucked object left behind when replacing the turbocharger air supply line

– suction elements together with the exhaust gases , eg . valves, injector tip , flip the suction manifolds , etc .

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5. Damage control valve turbo


Problems with turbochargers in concrete models

  • 1.6 HDi (Ford , Peugeot , Volvo, Mini , Mazda, Citroen )

Cause to seize up turbochargers were created in the bus the oil sludge Which can be formed by penetrating the exhaust gases from the injectors to OIL . Oil change every 30 thousand km and the use of low quality oil it’s another element that affects the lack of proper lubrication of the rotating turbocharger .

Assembly instructions and a special procedure for cleaning the oil system can be found on our Website ” instruction installation the turbocharger in the 1.6 HDI ”

  • Flaps in the vortex :

Fiat , Alfa , Opel, Saab- 1.9d

BMW- 2.0d , 3.0d

The mixture of oil mist connected with the exhaust gases from the exhaust gas recirculation system forms a precipitate on the lapels of vortex which are located in the suction manifold . At this point, the damper resistance larger air flows into the manifold . With long such action takes snap flap vortex which can damage the engine and turbocharger.

In order to avoid damage to the turbocharger in models equipped with the Vortex Valves to be carried out inspections and intake manifold CLEANING

  • Opel Insignia 2.0 CDTi Astra J

Lubrication Problems arise from the seals connecting the suction pipe oil with oil pump . After a long explantation seal loses its elasticity and does not seal the connection. In this case, in addition to the oil pump further incurs air. The result is a blurring of the turbocharger and / or the motor . In order to avoid faults should prophylactically replace the seal .

Oil spills , noise, lack of power

  •  Oil leaks from the compression :

-blockage or restriction in the supply air or air filter can a vacuum is produced which causes oil leakage from the compressor.

-to get through the additional air inlet ducts to the intercooler

-obstructed exhaust system including catalyst filter particulates

  • The causes of leakage from the exhaust (hot )

-leaks in the exhaust system

-leaks exhaust gas recirculation ( EGR )

-to clog Housing bearings

  • Causes of oil leakage on both sides

-repeat to switch off the engine is hot leads to deposition of carbon ( coke ) in the housing central

-damage to rotating parts turbochargers and excessive slack in bearings

-restriction oil flow in the return pipe turbochargers

In order to eliminate a failure :

-make sure that their exhaust air and oil are clear

-check whether the exhaust system for leaks

-make sure that the particle filter and catalyst are clear

  • No power

No power in the engine and turbocharger improper operation does not have to be associated with the turbocharger itself . The first thing to verify :

-system vacuum ( solenoid wires )

-cleanliness exhaust system

-system injection

-system exhaust gas recirculation

-sensor ( boost pressure sensor , flow meter, etc. ).

-potentiometr accelerator

-air filter

  • Noise

The noise coming from the turbocharger can be caused by:

-not balancing rotating system

-incorrect control relief valve or a variable geometry

-mechanical damage to the turbocharger

In other cases, the noise may come from :

-leaks Intake system

-leaks in the exhaust system

-or other items of equipment in the engine compartment


Installation instructions turbocharger in the 1.6 HDI

1.It carries out the procedure for flushing the motor according to the manufacturer’s cleaning agent.

2.To remove :

-oil coolers ( thoroughly cleaned )

-oil filter

-vacuum pump( thoroughly cleaned or replaced with a new one )


-oil line supply to the turbocharger ( replacement recommended new )

-the oil return pipe

-oil line consumption “dragon” ( the recommended replacement for new)

-oil pump

-air cooler ” intercooler ” ( thoroughly cleaned )


  • The procedure extended

If the oil indicates its high consumption (dense, solid fractions, tarry goo) must also:

-to remove valve cover and clean it with tar sludge from the bottom of

-to change outer seal the injectors


The procedure applies to vehicles manufactured extended to 2010.


During the manual cleaning of parts should also consider the possible condition of the engine. To do this, unscrew one foot shaft and check the main pan and crank or do not have signs of damage. If you experience excessive wiping check the overall condition of the engine.


Exactly clean the oil cooler

-for All the parts to assemble the new gaskets

-Check The air hoses for leaks, mechanical damage, barriers to movement entrusts pollution. Clean or replace with new ones.

-to assemble Turbocharger and elements previously removed

-when Assembling oil supply line to turbocharger to recommend is to remove the strainer from inside the screw

-pour engine oil

-to measure Amount of oil flowing through the turbocharger

-to turn on engine and leave it for 1 minute on low speed. The outer container drain the oil from the  return of the turbocharger. The amount of oil should not be less than 300ml.


If you have any questions regarding use of turbochargers and the methods by which you can increase their lifespan

– please contact phone . 691 525 456 , 669 008 077 .

Our specialists will take care to dispel any doubts arise .


+48 669 008 077

+48 691 525 456