Fact Sheet 7 - Hyundai Iload/Imax trouble shooting original turbocharger failure

• Turbochargers are very reliable: less than 1% of turbos fail due to a manufacturing fault with the turbo itself.
• 95% of turbo failures are because of problems with oil starvation, oil contamination or foreign object damage. 

BEFORE YOU FIT A NEW TURBO, FIND OUT WHAT CAUSED THE FIRST UNIT TO FAIL OR YOU RISK THE REPLACEMENT FAILING TOO.

Recommendation to do before installing New OE Turbocharger?

1. Remove the sump and clean sludge and oil pick up strainer.

2. Inspect the Cam Chain guide, this is made of Teflon and can delaminate and cause blockages.

3. Remove the Intercooler and clean, inspect all Intercooler hoses for cracks.

4. Remove the oil filter and cut open, inspect filter material for evidence of engine bearing material as this could indicate premature engine failure.

5. Inspect and check the flow through the oil heat exchanger, blockages can cause restricted flow of oil to the turbocharger.

6. Remove Injectors and inspect injector seals, worn seals can allow compression to leak up into the head, as well as a certain amount of diesel and combustion particles from the exhaust. Also combustion of the fuel would be incomplete and hence combustion particles would be greater than normal and deposits will form around the turbocharger VNT mechanism, causing it to become sticky or locked. This increase in combustion particles is also going directly into the head, making it very sludgy.

7. Remove air cleaner and replace with a genuine new unit.

8. Replace engine oil as per attached Hyundai specification.

9. Replace the engine oil feed pipe with a new genuine pipe.

10. Smoke test the vehicle to ensure no pressure leaks are evident, which may cause the turbocharger to over speed.

11. Inspect the catalyst to ensure the exhaust system is not blocked causing back pressure against the turbocharger.

12. Run a scan tool diagnosis to ensure all sensors and engine checks are operating correctly, replace any faulty parts, clear code and check again.