Join Date: Jan 2013
Location: United Kingdom
ALFA GT 1.9 JTD TURBO CLEAN
This method is normally required when the vanes within the VGT Turbo’s (Variable Geometry Turbo) stick.
The Carbon build up causes the vanes to stop working as they should – A service every 10k mikes to such turbos should be mandatory due to the design of these units being at fault.
They say the lifespan of these particular units is approximately 70/80k miles before they need replacing – Nonsense!
If serviced and maintained from 10k miles onwards then the longevity of these VGT Turbo’s should reach long past 120k+ miles
Items required before starting the service/clean: 1no INNOTEC Turbo Cleaning Kit, Blanking plate to hold the seal of card tight against the turbo, NEW gaskets where necessary, NEW fuel filter, NEW oil filter, New oil (Selenia WR 5w40/Castol Edge 5w40-fully synthetic) AND old clothes
1. Locate the exhaust side of your Turbo unit (This is best done with the car on a ramp/lift)
2. Leave enough room in order to allow sealing the turbo and making it easier to work – Check the internals for bearing movement as a NEW turbo maybe required
3. After sufficiently blanking the turbo opening with the card provided make a small hole big enough for the hose to fit through
4. Using something stronger clamped against the card making it a gasket to prevent leaks
5. Shake INNOTEC can 1 before connecting nozzle and hose then thread through the hole you made in the card and clamping plate
6. Thread tube into turbo and spray 1/3 of can 1 – Wait a few moments (during this time try and move the actuator arm – Use a vacuum appliance putting little pressure on the arm
7. Follow the previous step again (6)
8. AND AGAIN – only this time can 1 should now be empty (shaking the can as and when needed along the way)
9. Whilst leaving the contents of can 1 to work its magic for the next hour be sure to manoeuvre the Actuator arm as often as possible using the vacuum appliance
10. HOURS UP! The actuator arm should now be moving freely – Having an under tray/bucket at the ready is wise, as you now remove the Blanking plate/card from the Turbo
11. Shake INNOTEC can 2 and using the same hose, spray ¾ of it’s contents thoroughly in and around the inside of the turbo unit (wear goggles and use a cloth to eliminate spray offs etc)
12. Whilst leaving it to drip dry for a short period use this time to refit the NEW fuel filter – REMEMBER to add INNOTEC 3 fuel additive directly into the fuel filter
13. With the car back in the air be sure to use what’s left of INNOTEC 2 rinsing agent (Follow step 11) Clean thoroughly to get rid of what’s left and move the actuator arm again
14. Leave for 10 minutes and reconnect the Manifold/Exhaust back onto the Turbo using the new gaskets if required – wipe the exterior of the unit (Use carb cleaner if necessary)
15. Lower the car and check it over for any abnormalities – IF you haven’t done the FUEL FILTER & additive by now then be sure to follow STEP 12 before doing anything else
16. Start the car up and let idle for 3 minutes – On each minute rev to 3000rpm for just a second or two
17. Take the car for at least a 2 mile run (Engine needs to be at temp) – After the 1st mile be sure to use higher revs when changing through the gears
18. Now it’s time for the oil change (Piece of mind) – NEW Oil & Filter (Selenia WR 5w40 or Castrol Edge 5w40 Fully Synthetic recommended)
19. Car should now be good as new so long as the actuator arm is moving freely and the turbo is doing it’s job
• PLEASE NOTE: The internals should be inspected and checked before commencing the clean up – ANY loose bearings/breaks will not cure your Limp Home problems - Must be down to sticking Vanes.
• ALSO check various hoses and sensors before carrying out this exercise – i.e: MAF sensor, MAP sensor, EGR valve, Vacuum hoses, Turbo hoses and intercooler etc......
You will find details for ALL of these on the ‘Alfa Owners Club’ website