A WORLDWIDE COMPANY 05/09 GEN.03.

046/1

GENERAL
Problem: Cause:

TECHNICAL

BULLETIN

1.6 common rail diesel turbo charger damage

Making a good problem diagnose after turbo charger damage. Lack of lubrication due to a decreasing oil quality and (partially) blocked oil strainer and filters in the oil supply tube, the hollow bolt in the oil supply tube and in the vacuum pump. The contamination is caused by combustion residue in the engine oil as a result of incomplete combustion due to contaminated and leaking fuel injectors (bad spray pattern). Treatment:

First check the following parts for contamination.

Visible injector leakage.

Oil filter for excessive carbon and metal parts. Hollow bolt with fine metal gaze filter in the supply tube from the turbo. It can be mounted on the engine side or on the turbo charger side. Filter from the vacuum pump.

Oil filter, no excessive contamination

The removed metal gaze filter from the hollow bolt

Vacuum pump filter, no excessive contamination

If these parts are not contaminated excessively following the next procedure should be sufficient: Place the old oil filter back on the engine, it should be changed first after the internal cleaning treatment of the engine. Remove the filter from the hollow bolt. Clean the filter from the vacuum pump manually and replace with a new gasket. Replace the damaged turbo charger. Add 2 dosages Fort Advanced Diesel Fuel Conditioner to the fuel tank. Internal engine cleaning: Add 2 dosages Fort Motor Flush per 4 litre engine oil and run the engine idling for 60 minutes. Every 5 minutes shortly raise the engine speed up to 2.500 min-1 to get the maximum oil pressure.

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A WORLDWIDE COMPANY
05/09 Continuation of the General Technical Bulletin GEN.03.046/1

Replace the engine oil and oil filter. Add 1 x Fort Top End Treatment per 4 litre new engine oil. Next road test the car for 40 kilometres and perform a final check. After the test drive during cold situation the return amount of engine oil from the turbo charger is measured. Let the engine idling for 1 minute and collect the return oil. This should be at least 300 ml. If the return oil amount is enough, the car can be returned to the driver.

If these parts are heavily contaminated than the following procedure should be carried out:

Excessive contaminated oil filter

Blocked filter in the hollow turbo charger bolt

Heavily contaminated vacuum pump filter

If these steps are not done properly the diagnose will be incomplete resulting in unrepairable engine damage: The following parts must be demounted and checked for contamination: The sump The oil strainer and the suction tube The oil filter housing The oil return tube from the turbo charger The oil supply tube from the turbo charger

New and contaminated oil strainer and suction tube

Contaminated sump

Bad quality oil from the vacuum pump oil channel

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A WORLDWIDE COMPANY
05/09 Continuation of the General Technical Bulletin GEN.03.046/1

Damaged big end bearing

Damaged big end tap

Damaged crankshaft tap

To determine engine damage remove one connecting rod bearing and check the big end and big end bearing for wear. If severe wear is determined one should check for wear in the engine generally. If damage is not visible carry out the following actions carfully: The following parts should be cleaned well and mounted back again: The oil filter housing and the connecting sealing surface and opening on the engine. Place the oil filter housing with a new gasket. The vacuum pump and replace with a new gasket. Place the new oil supply tube from the turbo charger. Mount the sump with new fluid gasket (prevent excessive product!) Demount the intercooler and the intercooler tubing and check for damage of cracks. Clean the parts and replace them on the engine or replace the new parts. Carefully mount the new turbo charger. See the turbo charger mounting instructions. Check the oil supply tube from the turbo charger and replace if doubtful. Remove the small metal gaze filter from the hollow bolt. If the hollow is replaced for a new one, take out the filter as well. Carefully check the complete air intake including the air filter for damage or leakage. Replace the oil filter and top up the engine oil to minimum level. Start the engine and take the following steps: Check the oil pressure as prescribed by the manufacturer. Add 2 x Fort Advanced Diesel Fuel Conditioner to the fuel tank. Clean the engine internally. See the explanation on page 1. Replace the oil filter and engine oil after the cleaning treatment. Add 1 x Fort Top End Treatment per 4 litre new engine oil. Next road test the car for 40 kilometres and perform a final check. After the test drive during cold situation the return amount of engine oil from the turbo charger is measured. Let the engine idle for 1 minute and collect the return oil. This should be at least 300 ml. If the return oil amount is less, the engine is suffering from too much internal leakage on crankshft, connecting rod and camshaft bearings.. If the return oil amount is enough, the car can be returned to the driver.

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