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Failed Turbo replaced, what to do next?
#1
Last month the turbocharger on my 106000 mile 2007 1.6HDI van failed in time honoured fashion - spindle nut off, turbine shaft snapped, turbine blades chewed up. After being quoted the thick end of £2000 to fit a reconditioned unit and do the necessary remedial work, I fixed it myself. I have....

Fitted a new CHRA core from 'Direct Turbo UK'
Fitted a new sump pick up, cleaned out and resealed sump.
Drained about 50ml of oil from the intercooler.
Fitted a new oil extract pipe from the turbocharger.
Fitted a new oil supply pipe & banjo bolts to the turbocharger with filter omitted.
Replaced oil filter and refilled with Quartz INEO ECS 5w30 oil.
Fitted a new cam cover because PCV valve was passing too much oil.
Fitted an oversized rubber O ring on the air duct to cam cover connection to make it airtight.

Since doing this work I've made a 120 mile round trip and all seems OK but I'm just wondering what comes next? 
I've read so many accounts of people who have done similar remedial work only to have the new turbo fail after a short time. I would appreciate any thoughts regarding the work I've carried out and any suggestions for further work which might give me a chance of long term reliability.
 
I have to use the van for about 30 miles this weekend, after which I'll be renewing the injector seals as there is a fair quantity of carbon crud around injectors 3 and 4. I have the seals, seat reaming tool and 14mm crowfoot but I'm not planning to replace the HP pipes as mentioned in the Haynes manual, any comments on this are invited. I will also change the oil and filter again at this time.

Lastly, I'd like to thank all the contributors to these forums as it has been an excellent source of reference during my ownership of the van and was especially useful whilst carrying out the turbo replacement.
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#2
There is a mesh filter on the vacuum pump you may want to clean. Other than that you have covered most things but do keep changing the oil and filter every 1000 miles for about the next 5k just to make sure you have all the sh1t out of the engine.

HP injector pipes only change if you have trouble sealing them.
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#3
Thanks Polar  Smile
I cleaned out the vacuum pump today, I'd say a third of the little filter was covered in deposits, so that should help.

Anyone know how long it takes for injector rail/pipe pressure to dissipate after the engine is turned off? 
I'm planning to get the engine nice and hot this weekend and (hopefully) yank out injectors 3 & 4 with mole grips before the carbon around them has a chance to cool down and solidify.
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#4
Yes also ive been told coke poured on and left overnight will help! Personally i would use cellulose thinners and give it a good soaking overnight.

Not sure on the fuel rail - just undo the unions very very carefully
[-] The following 1 user says Thank You to polar for this post:
  • PJR_247
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