Tip & How-To about Mazda MAZDA6

Turbocharger installation

In order to avoid any possible damage while installing your turbocharger or premature operating problems, either of which could invalidate the warranty, please follow these simple intructions carefully and completely.
1) Ascertain why the old unit failed, you don't want the same problem to recur and damage the new unit.
2) check for cleanliness. the smallest particles of dirt can do irrevocable damage to a turbocharger so check engine intake/exhaust and aftercooler systems for cleanliness and obstructions, carefully removing oil, pieces of gasket, dust, dirt and other debris. Replace the air filter.
3) Check the oil inlet and oil drain flanges are clean and free from obstruction, internal carbon and sludge, removing them to clean if necessary. if in doubt replace with new.
4) Replace the oil and filetr
5) Check that manifold casting is not cracked on the outside or breaking internally.
6)Mount the turbocharger on the exhaust flange checking that turbine inlet gasket fits correctly to give a gas tight seal.
7) Connect the oil drain pipe using gasket supplied - do not use any liquid gasket products.
8) Fill the tubocharger oil feed hole with clean engine oil and rotate the rotor by hand.
Finally connect all external fitting to the turbocharger. Start the engine and idle for few minutes, check the oil is not leaking and the warning sign does not come up, check all connection for possible leaks using soapy water.

Posted by on

Cars & Trucks Logo

Related Topics:

Related Questions:

1 Answer

ODB Code P1557


Trouble Code: P1557

Charge Pressure Control Positive Deviation

Possible Causes:


Charge air system leaks.Recirculating valve for turbocharger is faulty.Turbocharging system is damaged.Vacuum diaphragm for turbocharger needs adjusting.Wastegate bypass regulator valve is faulty.ECM has failed.Here's the causes for the code.

Nov 27, 2012 | 2001 Volkswagen Beetle

1 Answer

how do you know the turbo is bad in a 1988 t-bird


Hello there and welcome to fixya

Turbocharger problems are some of the most difficult to troubleshoot. The main purpose of the turbocharger is to provide more air to the engine. The more air going into the engine the more fuel that can be burned, which results in an increase in horsepower. There are four main parts of the turbocharger: the wastegate, center rotating assembly, turbine housing and the compressor housing. By understanding how the turbocharger functions, it is possible to uncover the causes of problems.
Difficulty:Moderate Instructions

    • 1 Check the air filter element as this is a main cause of blue exhaust smoke. This blue smoke occurs when there is not enough air going into the engine. Check all ducts and pipes for obstruction or leaks.
    • 2 Clean the turbocharger. Dirt that has caked onto the compressor wheel or the diffuser vanes can cause all types of problems. If the turbocharger is very dirty or the center housing contains sludge then you should also check the filters. Dirt coming in to the turbocharger is most likely due to broken filters.
    • 3 Check with the engine manual to ensure that the camshaft or pump is working at the correct timing. Adjustments may need to be made as the turbocharger can change over time. If the turbocharger is out of sync, then this will result in a noticeable decrease in engine power. An additional cause of decreased power is a gas leak in the exhaust manifold or the turbine outlet duct. The less gas the less power that is produced.
    • 4 Check the turbine blade and compressor for any damage such as indentations or notches. This type of damage will cause screeching noises, whining noises, rattling and scraping sounds. You will need to replace the turbocharger as well as locate the source of the damage to prevent further damage. There is a chance that the noises are due to other eternal components and not the turbocharger, but a visual inspection is easy to check before moving onto other components.
    • 5 Inspect the actuator if the entire turbocharger is frequently overboosting or underboosting. Make sure that the actuator is not loose and if so tighten it to the specified torque values. If there is visible damage to the actuator and air leak or if the actuator spring has broken a new actuator is needed.

Aug 28, 2011 | 1988 Ford Thunderbird

2 Answers

HOW TO INSTAL QUICK STRUTS ON A CHEVROLET MONTE CARLO 2003


Hello dedime,
Removal

1. Remove the nuts and bolt attaching the top of the strut assembly to the body.

2. Raise and support the vehicle. Refer to Vehicle Lifting.

3. Place jack stands under the front cross member.

4. Lower the vehicle slightly so that the weight of vehicle rests on the jack stands and not on the control arms.

Notice: Care must be exercised to prevent the drive axle joints from being over-extended. When either end of the shaft is disconnected, over-extension of the joint could result in separation of the internal components and possible joint failure. Drive axle joint boot protectors should be used any time service is performed on or near the drive axles. Failure to observe this can result in interior joint or boot damage and possible joint failure.

5. Remove the tire and wheel assembly.

6. Remove the brake line bracket.

7. Scribe the strut flange.

Important: The steering knuckle must be supported in order to prevent axle joint over-extension.

8. Remove the bolts and the nuts attaching the strut to the steering knuckle.

Notice: Care should be taken to avoid scratching or cracking the spring coating when handling the front suspension coil spring. Damage can cause premature failure.

9. Remove the strut from the Vehicle.

Installation Procedure

Notice: Care should be taken to avoid scratching or cracking the spring coating when handling the front suspension coil spring. Damage can cause premature failure.

1. Install the strut into position and install the nuts and one bolt connecting the strut to the body. Hand tighten the nuts and the bolt.

2. Align the steering knuckle with the strut flange scribe mark and install the bolts and nuts. Tighten the nuts to 180 Nm (133 ft. lbs.).

3. Tighten the nuts and bolt attaching the top of the strut to the body. Tighten the nuts to 25 Nm (18 ft. lbs.).

Tighten the bolt to 25 Nm (18 ft. lbs.).

4. Install the brake line bracket.

5. Install the tire and wheel assembly.

6. Inspect the front wheel alignment.

Regards,

netvan


Feb 22, 2011 | 2003 Chevrolet Monte Carlo

1 Answer

Smoking Vehicle After servicing.


Ther first code ECM-6805 TURBOCHARGER (TC) CONTROL VALVE DIAGNOSTIC TROUBLE CODE (DTC) INFORMATION If engine speed (RPM) is above 3500 rpm and the engine is operating at a high load, and if the boost pressure (from the boost pressure sensor) is higher than a designated value, which at maximum boost pressure is approximately 20kPa (2.9psi) above normal boost pressure, this is interpreted as a fault and diagnostic trouble code (DTC) ECM-6805 is stored. Condition reduced boost pressure Possible source * hoses between turbocharger (TC) and turbocharger (TC) control valve respectively turbocharger (TC) control valve and pressure servo are loose or are blocked/damaged * faulty turbocharger (TC) control valve * faulty boost pressure control (BPC) valve pressure servo * sticking boost pressure control (BPC) valve Condition * none ECM-6805 TURBOCHARGER (TC) CONTROL VALVE PRESSURE TOO HIGH - PERMANENT/INTERMITTENT FAULT Checking the hoses and turbocharger (TC) control valve Check that the hoses between the intake manifold, pressure regulator and turbocharger (TC) control valve are not trapped, blocked or damaged. Check the turbocharger (TC) control valve by activating it. Check the alignment of the boost pressure control (BPC) valve pressure servo and the boost pressure control (BPC) valve and that they are functioning correctly and not sticking according to See: Component Tests and General Diagnostics\Boost Pressure Regulator, Checking/Adjusting Verification Hint: After carrying out the repair, check that the fault has been remedied. * Ignition off. * Reinstall connectors, components etc. * Disconnect the VCT 2000 from the data link connector (DLC). * Test drive the car and check that high boost pressure is obtained. * Connect the VCT 2000 to the data link connector (DLC). NOTE: Do not switch off the ignition before the VCT 2000 has been connected and the boost pressure has been tested with the smart tool. Read the boost pressure fault status When the boost pressure has been tested the display should show that the diagnostic is complete. the second code Symptoms You will likely not notice any serious drivability problems, although there may be symptoms. Possible Solutions The simplest thing to do is to reset the code and see if it comes back. Then start with the cheapest, easiest repair procedures: Inspect for the following conditions: An incorrectly routed harness--Inspect the harness of the MAF sensor in order to verify that it is not routed too close to the following components: - The secondary ignition wires or coils - Any solenoids - Any relays - Any motors A low minimum air rate through the sensor bore may cause this DTC to set at idle or during deceleration. Inspect for any vacuum leaks downstream of the MAF sensor. A wide open throttle (WOT) acceleration from a stop should cause the MAF sensor g/s display on the scan tool to increase rapidly. This increase should be from 6-12 g/s at idle to 230 g/s or more at the time of the 1-2 shift. If the increase is not observed, inspect for a restriction in the induction system or the exhaust system. The barometric pressure (BARO) that is used in order to calculate the predicted MAF value is initially based on the MAP sensor at key ON. When the engine is running the MAP sensor value is continually updated near WOT. A skewed MAP sensor will cause the calculated MAF value to be inaccurate. The value shown for the MAP sensor display varies with the altitude. With the ignition ON and the engine OFF, 103 kPa is the approximate value near sea level. This value will decrease by approximately 3 kPa for every 305 meters (1,000 feet) of altitude. A high resistance on the ground circuit of the MAP sensor can cause this DTC to set. Any loss of vacuum to the MAP sensor can cause this DTC to set. the third code O2 sensor failure may not be displayed appropriatly

Jun 08, 2009 | 1997 Volkswagen Jetta

1 Answer

Check engine light on came on in my 2005 VW Jetta TDI. Pulled code using auto parts store code reader and the only fault noted was ''turbocharger boost control position sensor circuit low''. Can you tell me what to expect in order to address this message, and is this something that can cause problems if I continue to drive car? Other than light on, there isn't any noticeable change in car.


There may be a possiblity of doing damage to the turbo if you continue to drive it this way. I would recommend either taking it to the dealer or a reputable repair shop in your area to have this repaired as soon as possible, as to not risk damaging the turbo. Hope this helps.

Mar 11, 2009 | 2005 Volkswagen Jetta

Not finding what you are looking for?

2,253 people viewed this tip

Ask a Question

Usually answered in minutes!

Top Mazda Experts

yadayada
yadayada

Level 3 Expert

76109 Answers

Colin Stickland
Colin Stickland

Level 3 Expert

22156 Answers

Jeff Turcotte
Jeff Turcotte

Level 3 Expert

8270 Answers

Are you a Mazda Expert? Answer questions, earn points and help others

Answer questions

Loading...