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Turbo Diesel News From Denco Diesel

Training, Tips and Industry News designed to have your Turbo Diesel running at peak performance.

Last Build Date: Mon, 29 Feb 2016 06:54:49 +0000


What is a Power Pedal and do I need one?

Tue, 23 Feb 2016 00:45:25 +0000

(image)  There are so many automotive products on the market it’s hard to sift through what would be beneficial and what is just an unnecessary extra. Power Pedals are really starting to take off in the market and Steinbauer are keeping up with an ever increasing range. We thought we would visit the Power Pedal and see what it is all about, which really comes down to these 3 questions. What is a Power Pedal? 1. A Power Pedal is an aftermarket accessory designed to increase throttle response to Electronic Fuel Injected (EFI) and Common Rail Diesel (CRD) vehicles. What does it do? 2. The Power Pedal alters the signal read at the TPS (throttle position sensor) so the vehicles ECU (Engine Control Unit) provides better response, overcoming initial turbo lag. Do I need one? 3. If your vehicle feels unresponsive in first gear (typically before the turbocharger ‘kicks in’) and/or you need to ride the clutch to build revs so the vehicle doesn’t stall, the power pedal will help in overcoming these problems. So in a nutshell that is the power pedal and what it does. This is what a power pedal looks like: Buy 230018 POWER PEDAL D40 NISSAN NAVARA / PATHFINDER & HOLDEN CRUZE The following video shows the ease of fitment on a Nissan Navara D40 (they are all similar to this in ease of fitment) PRICE: $445 RRP For a limited time – take advantage of FREE shipping Australia Wide (online orders only)

Surging in a Nissan Patrol / Navara 3ltr with ZD30 engine

Tue, 08 Dec 2015 02:45:45 +0000

(image)  (VP44 style pump, with manual transmission)  Vehicle Symptoms Cruising in 3rd or 4th gear a surge will occur with no D.T.C. (Diagnostic Trouble Code) It can occur in all gears but problem is mostly seen in 3rd and 4th gear. Vehicle: Nissan Patrol 3.0L with ZD30 direct injection engine Nissan Navara 3.0L with ZD30 direct injection engine Date code: 2000-2006 (with VP44 style pump) Description The vehicle will surge or intermittently go into limp home mode when driving in either 3rd or 4th gear. The neutral position sensor briefly loses the position of the gear and the ECU (thinking the vehicle is in neutral) reduces fuel quantity. With the ECU constantly changing fuelling as it responds to the vehicle being in gear then in neutral then back into gear it results in a surge condition. To simulate this problem, take the vehicle on a test drive. When the vehicle begins to surge move the gear stick laterally and hold it in place. If the surge goes away while holding the gear stick in position and begins surging again after you release the gear stick it indicates that the neutral position sensor is faulty. Solution: Replace Neutral Position switch on vehicle  

Pressure Box or Power Module?

Fri, 30 Oct 2015 01:00:24 +0000

(image)  PRESSURE BOX OR POWER MODULE? If you are looking for a quality product to increase your vehicle’s efficiency, power and torque, that has been tried, tested and sold worldwide – then there is only one. STEINBAUER. Quite simply there is no substitute for quality. Features include: tested & sold worldwide, operating in all climates & conditions robust construction, dust, moisture and vibration resistant quality European engineering and components easy installation no increase in rail pressure backed by a worldwide support network One major feature the power module has over all others is an in built safety feature which stops any undue stress or damage to the engine should the vehicle be put under full load for a sustained period of time. The module will cut the fuel back 1% per 1 second until it reaches a deemed safety net and it maintains this decreased power percentage until throttle is released. The module clears itself and goes back to functioning as per normal. Major benefits and features that are exclusive to the Steinbauer Power module that other chips on the market do not offer: Plug and play: a bridging harness is supplied connecting module to vehicle. No cutting wires, easy to take back to standard factory set up. Plugs into each injector (common rail) or plugs direct into the injector pump and not the ECU Does not alter the ECU, injection timing or change fuel pressures Includes a potentiometer to increase / decrease power Can include a switch on your dash to turn the module on and off as needed. Safety feature to cut fuel back on full load, stopping undue stress on the engine. There are many products on the market today that claim to increase power and torque. Buzz words like chip tuning, chipping or flashing are technologies of the past. These are products that increase rail pressure and are simplistic technology – increasing rail pressure can cause major engine failure. Increasing rail pressure can cause problems with your vehicle as it is putting higher pressure and volume through the pump and injectors, which in turn can cause premature wear to the fuel system. The increased fuel pressure can also potentially cause your vehicle to go into limp home mode as a result of the ECU detecting pressure fluctuations or higher than normal fuel pressure. The Steinbauer power module modifies the injection system by fine tuning the duration of the injectors. This is achieved by blue printing the original characteristics and intercepting the electronic signals from the ECU to the injection system. The fuel injection and engine speed are recorded and recalculated to optimise performance. The module lengthens the injection pulse width, altering the fuel map based on the engine conditions and engine speeds. It does not alter the ECU, change injection timing or alter fuel pressures. CHOOSE THE BEST FOR YOUR VEHICLE!  

Are non-genuine turbo parts really an option?

Thu, 22 Oct 2015 05:58:35 +0000

(image)  Everyone wants to save a buck but are non-genuine parts really an option? SCENARIO You send your turbo into the local turbo repair specialist who is able to repair your turbo, no problems, but uses non – genuine parts for a much cheaper repair. Sounds great! Right? More money in your back pocket means more money for the next project! Unfortunately this is generally not the case. Using non – genuine parts in a repair can result in your vehicle having: Poor performance Low boost Poorer fuel economy Premature failure of the turbo Engine failure Saving a few bucks on your turbo repair only to have your vehicle break down as a result of inferior parts used in a repair can have you spending big bucks in the long run. Some of the costs can include: Paying for a tow truck Being without your vehicle for unknown period of time Replacement of not only your turbo but potentially intercooler (or engine) if the turbo fails and fractured pieces of the compressor wheel shoot into the inlet manifold. Are you getting what you paid for with your turbo repair? It’s worth asking the question when your repair is being quoted to save a lot of time and frustration down the track. Having your turbo repaired using only genuine parts ensures that the turbocharger meets the original specifications.

Denco Relay for Life 2015

Tue, 13 Oct 2015 22:59:33 +0000

(image)  We had the pleasure of attending our first relay for life on the weekend and what a great community event it was! Miss Denco Rub even made an appearance. It was so nice to see so many people come together and raise money to kick cancer’s butt!  

Photo Gallery of a Toyota Landcruiser 2H Turbo Kit Install

Mon, 28 Sep 2015 02:00:58 +0000

(image)  It is said pictures can tell a thousand words: Here are some photos of a Denco turbo kit install on a Toyota Landcruiser HJ60 done in our workshop recently.    

Shauno’s visit to Denco

Thu, 20 Aug 2015 03:29:23 +0000

(image)  Just had the pleasure of meeting Shauno and Chris from 4WD Action, great guys and what an amazing job they have! They were down filming a few segments for the next 4WD Action DVD and mag. We can’t wait to see how it all turns out, they were pretty amazed with our machine shop so I am betting there will be some great footage there! Here is Shauno’s V8 Toyota Landcruiser on our dyno, great looking vehicle with, I am sure, more modifications to come, in fact he has just left with one of our waterscan systems (TOYSCAN-4) to fit up.   I’m down at Denco and we put the 79 on the dyno. Stock engine and aftermarket exhaust on 35s she spits out around 140hp at the wheels and 355 lb-ft torque. It’s good to see where I’m starting from Posted by Shaun Whale on Tuesday, August 18, 2015

Media Files:

Turbo Failure Ford Falcon

Thu, 30 Jul 2015 22:57:00 +0000

(image)  Such an easy check can prevent your Ford Falcon turbo failing. There is an inline filter in the oil supply pipe to the turbo in a Ford Falcon (located in the fitting which screws into the block). This filter is often forgotten about during servicing of the vehicle. If it is not regularly checked / cleaned / replaced it can block up, restricting oil flow to the turbocharger which will inevitably lead to premature turbocharger failure from insufficient lubrication to the bearing cage. The inline filter is a genuine Ford part and can be sourced from your local Ford dealer. The genuine Part number for the turbo inline filter in a falcon BA / BF is : SY9P424A

How to time a VE Style fuel pump

Tue, 21 Jul 2015 03:50:09 +0000

(image)  Timing a VE Style Fuel Pump The following instructions are compiled from the YouTube Video below instructing on how to time a VE style fuel pump.   Topics Covered Introduction of Scott Wood – Director at Denco Diesel + Turbo Safety Checks and Degree of Difficulty Introduction of VE Style Pump and Vehicle Pump Variations – Explanation of TDC, ATDC, BTDC, ACSD Tools Required Specific Timing Specifications for common vehicles Installing the Dial Gauge and Timing Bracket DISCLAIMER: If you are to adjust the timing on a vehicle’s pump you are doing so at your own risk. Denco Diesel and Turbo take no responsibility for your actions and suggest that you take all necessary safety precautions to ensure the safety of yourself , those around you and the vehicle. Denco Staff Member:    Scott Wood Introducing Scott Wood, National Service Manager and Director at Denco Diesel and Turbo Scott has over 25 years experience in diesel fuel injection and is a factory trained technician as well as one of the directors of Denco Diesel and Turbo. Vehicle Safety Checks General Safety checks should be carried out prior to attempting to time a vehicle. Safety checks such as: Ensuring the vehicle has been turned off The vehicle has been secured with chocks Keys are removed from the ignition and that the vehicle is in neutral with the handbrake on.  Introduction of VE Style Fuel Pumps   VE Style Fuel pumps are commonly fitted to the following vehicles (pre common rail): Ford Courier Mitsubishi Triton Toyota Hilux Toyota Landcruiser Nissan Patrol Early Nissan Navara Mazda Bravo Pictured Below: Fuel Pump to suit Toyota HZ Landcruiser Pump variations Within your manufacturers manual you will find specific timing specifications for your vehicle. We also list common timing specifications below. Depending on the variation of your pump, your specifications will be given for TDC, ATDC and BTDC.        TDC = Top Dead Centre        ATDC = After Top Dead Centre        BTDC = Before top dead centre        ACSD = Automatic Cold Start Device – Requires 8mm Spacer for timing Put a metal plate (thickness of approx. 8mm) between the cold starting lever and thermo wax plunger   To release ACSD advance: Using a screwdriver, turn the cold starting lever counterclockwise approx. 20° Put a metal plate (thickness of approx. 8mm) between the cold starting lever and thermo wax plunger. Specialised Tools Required   Timing Tool Bracket NOTE: Use this tool along with a dial gauge (available at any auto shop) to assist you in timing your VE Style fuel pump, Dial gauge must have minimum 5mm travel. 95095-10400 Timing Tool Bracket    Available for purchase here                           Specific Timing Specifications Common Toyota PUMP TIMING SPECIFICATIONS Toyota Hilux L                                2.2ltr                       0.94-1.06mm @ TDC Toyota Hilux 2L                              2.4ltr                       1.06-1.22mm @ TDC Toyota Hilux 3L                              2.8ltr                       0.86-0.94mm @ TDC Toyota Hilux 5L                              3.0ltr                       0.64-0.76mm @ TDC Toyota Dyna                                  B                           0.54-0.66 with ACSD with […]

Denco Diesel & Turbo takes out Bosch Oceania Award

Sun, 05 Jul 2015 21:30:46 +0000

(image)  Denco Diesel & Turbo takes out Bosch Oceania Award In recognition for excellence, the team at Denco Diesel & Turbo have taken out the 2014 Excellence Award for Oceania. Wagga Wagga, NSW, 6 July 2015 – Denco Diesel & Turbo have won the 2014 Excellence Award for NSW and Oceania. The award was presented at the Bosch Service Network convention at Manly on Saturday 6th June 2015 by Stuart Howe, Regional Workshop Concept Manager for Oceania Automotive Aftermarket. This is the first time Denco Diesel & Turbo have received both the state and oceania awards. “There is a lot that goes on behind the doors to ensure that we continually deliver on our promise to provide excellent service to our customers each and every time. Our repair staff are committed undertake training and then delivering that expertise on each repair. Our support staff strives to deliver the best customer experience. Our modern workshop utilises the latest equipment which is regularly audited by the manufacturers. The very best quality genuine product goes into each repair. So its fantastic to have that behind the scenes commitment recognised by Bosch with the 2014 Bosch Excellence Award.” said Scott Wood Service Manager, Denco Diesel and Turbo. It is important to note that other dealers in the network are required to nominate businesses to be considered for the award, a feat that hasn’t gone unnoticed by Denco Diesel and Turbo. “Our customers demand the best, and I think this award acknowledges our commitment to delivering the best quality product to them.” Dench Diesel and Turbo also received 100% in their recent audit.

Nissan Patrol ZD30 ETi Turbo Service Bulletin

Fri, 03 Jul 2015 04:43:07 +0000

(image)  Nissan Patrol ZD30ETi TURBO SERVICE BULLETIN PART NO: 724639-5006 / 724639-0006 / 724639-5006S OEM PART NO: 14411-VC100 / 14411-VC200 / 14411-2X900 / 14411-2X90A / 14411-VB100 Before replacement of this turbocharger the following information should be taken into consideration Turbocharger failures are generally the result of external influences and there have been instances of recurring turbocharger failures for this application. In some circumstances the turbocharger can overspeed and cause excessive boost (or a boost spike), and the vehicle will temporarily go into limp home mode. The overspeed of the turbocharger can be caused by, but not limited to a low signal voltage from the air flow sensor. It is recommended to insure that the air mass voltage is checked and is within the manufacturers’ specification. If the air mass sensor is not operating correctly and the vehicle continues to be driven, it can cause premature turbocharger failure. The engines lubrication and engine management system must also be checked to eliminate further possible causes of recurring turbocharger failure. If the initial turbocharger failure is unknown it should be assessed by a turbocharger technician prior to fitment of the replacement unit. As the above failures are caused by external factors outside of the manufacturer or suppliers control, any failures resulting from the above conditions will not be considered for warranty.

Recurring turbo failure for Hyundai ILoad & IMax

Wed, 27 May 2015 00:02:35 +0000

(image)  Recurring Turbo failures for Hyundai ILoad and IMax Turbo Part Number: 53039880145 / 53039700145 OEM Part Number: 28200-4A480  Service Bulletin  Prior to fitment of the replacement genuine turbocharger it is important to determine the original cause of failure to prevent reoccurring turbocharger failures. As per the technical service bulletin SE07812 the following must be inspected to assist with the diagnosis of the root cause.   Inspect turbocharger for any damage Excessive shaft radial & axial play or damage to the rotor assembly blades Bent and/or broken shaft Carbon build up within the nozzle ring assembly (inside VGT system)   Inspect intercooler assembly Inspect for split fins with oil contamination   Inspect oil pick-up screen Inspect screen for carbon blockage   Inspect injectors Inspect for evidence of leaking washers and carbon build-up around outside of the injector body   Inspect the injector seat in cylinder head for damage   The above conditions may result in combustion gases entering the engines crankcase resulting in excessive blow-by and carbonising/thickening of engine oil.   Note: Poor vehicle servicing or incorrect engine oil specifications can also result in the above failures and should not be confused with poor injector sealing as the root cause.   SERVICE REQUIREMENTS WHEN SERVICING INJECTORS If injectors have been leaking compression past sealing washer (resulting in carbon contamination in oil and blockage of oil pick-up), the injector holes within the cylinder head will need to be cleaned of any carbon build-up to ensure sealing integrity and the injector washers will need to be replaced. Failure to remove all carbon deposits from the injector holes will result in repeat blow-by. Injector clamp bolts need to be replaced with new bolts and ensure the torque is set to specification. Note: Engine oil and oil filter must be replaced if compression has leaked past the injectors.   TYPES OF TURBOCHARGER FAILURES & CAUSE Combustion gases entering the engines crankcase, poor servicing of the vehicle or incorrect grades of oil can result in a number of ensuing issues with the turbocharger; A reduction of oil quality to the turbocharger causing premature bearing and shaft wear, and potentially shaft fracture Insufficient or interrupted supply of oil to the turbocharger causing premature bearing and shaft wear, and potentially shaft fracture   Split silicone hoses between the turbocharger, intercooler and inlet manifold (and/or intercooler leaks) can also allow the turbocharger to overspeed. This is due to the turbo ‘over working’ to overcome the loss of boost pressure due to the pressure leaks. Overspeed failures result in compressor wheel fatigue (loss of a blade, or complete fracture) with secondary failures such as shaft fracture.   Denco Diesel & Turbo can also assist with turbocharger failure analysis (if the above diagnosis points are unable to be determined) by disassembling the original failed turbo for internal inspection. While not completely conclusive (some turbocharger failures are so catastrophic that root cause is difficult to ascertain), it can be helpful in finding the original fault or in the very least point you […]

Toyota Hilux pump seized

Thu, 30 Apr 2015 01:37:41 +0000


Mazda BT50 Common Rail pump failure

Thu, 30 Apr 2015 01:17:18 +0000


Water in Common rail Diesel fuel system

Wed, 29 Apr 2015 04:24:20 +0000

Most common rail engine failures can be prevented. Read on to find out how you can help your common rail diesel stand the test of time. Water is the most damaging fuel contaminant in a common rail fuel system, it creates a lack of lubrication in the fuel system which in turn can prematurely wear your high pressure pump and injectors. We see at least 3 water in diesel fuel related failures per week, sometimes more, particularly in common rail systems. The high pressure pump and injectors used in a diesel common rail vehicle rely on good quality fuel, they have a high failure rate when water contamination is present.

Repairing John Deere 4440 Injectors

Tue, 28 Apr 2015 04:36:44 +0000

Our guess is the rust and nozzle wear on these John Deere 4440 Injectors is just from time, wear and tear and weather.

VNT Turbo Repair

Thu, 23 Apr 2015 02:32:25 +0000

VNT Turbo Repair 2 turbos came in today, both had failed on a Hino J08E 500 Series Truck. Upon inspection it became obvious that the turbocharger had been repaired (which had been carried out as an unauthorised repair of a Garrett VNT Turbocharger using non-genuine  components);We do not repair VNT turbochargers in our workshop, Garrett Turbo have a strict non repair policy on all of their VNT turbos and as a distributor of their turbos we are not authorised to repair. Genuine replacement parts for Garrett VNT turbochargers are not available and therefore a GENUINE authorised repair can not be carried out. These pics show the cause of failure

Turbo failed twice – find out why!

Wed, 22 Apr 2015 23:19:12 +0000

TURBO FAILED TWICE – FIND OUT WHY! A customer called last month looking to replace a turbo for one of their customers, we supplied them with a brand new GENUINE Holset turbocharger which they onsold to their customer. This turbo also failed. As a general rule turbos don’t just fail – there is usually an underlying issue, split intercooler or  hoses, oil restriction or an existing engine condition. A lot of the time the turbo is the first to cop the blame but more often than not it is not a turbo issue. Our customer requested a new turbo again before having the first turbo assessed to see why it had failed, their customer requested this as they could not afford any downtime, however another BRAND NEW GENUINE TURBO failed immediately. Extra costs and more time off the road. This immediately rang alarm bells to us – there must be an existing condition that caused both these turbos to fail identically. Upon inspection of the second failed turbocharger we found the parts to be heat effected from an interrupted or restricted oil supply.

Repairing Toyota 1HZ Diesel fuel Injectors

Thu, 16 Apr 2015 05:00:56 +0000

(image)    Worn injectors can cause lots of issues with your diesel 4WD – fuel economy and smoke issues are at the top of the list! Jason from our workshop sent through a few photos today that I thought were worth sharing. These are some before and after shots “I checked first and found them to have worn nozzles, I then advised customer who wanted to proceed with the job.”         “So we check over, then go to cleaning process, recheck, renew worn parts, new genuine nozzles fitted and pressure adjusted on Bosch calibrated pop tester to manufacturer specifications, bagged and supplied with a new washer kit.               Our service exchange injector stock follow this exact same procedure and can be purchased prior to sending your own units back saving you downtime.