ZEST BOLT Service Manual

Revotron 1.2T 44 E. Brake Binding : During driving apply brakes number of times and then shift gear to neutral position and check free rolling of vehicle. Check brake drums/brake discs for overheating and if necessary jack up the vehicle and check wheels for free rotation. F. Turbocharger : Check for Tuning 1. Check intactness of actuator rod end. 2. Collapsed or restricted air pipe before turbo 3. Check for crank bent or actuator rod bend or hose pinch. 4. Restricted or damaged cross over pipes turbo to inlet manifold 5. Foreign object between air cleaner and turbo 6. Compressor./ Turbine Wheel damage due to Foreign object entry 7. Turbine bolts, Compressor bolts, actuator bracket bolts, or Clamps loose. 8. Check Air filter for any blockage 9. Check for excessive back pressure. The Paint seal should not be broken. If not OK the turbo charger must be replaced. Check Turbocharger compressor wheel damage 1. Disconnect Compressor Air inlet pipe. 2. Inspect compressor wheel blade. 3. There should be no visible damage. If damaged, the turbo charger must be replaced The entire air circuit must be cleaned or changed to avoid new failure in case of foreign object The foreign object can be found in the heat exchanger Check Turbocharger rotor movement 1. Check rotor movement, it should spin freely. 2. There should be no trace of contact with housing. If not OK the turbo charger must be replaced Check Turbocharger Turbine wheel damage 1. Disassemble Turbocharger or exhaust gas connection. 2. Inspect turbine wheel rotor damage. you need to look behind the blades, damages are often located in tip area If damaged, the turbo charger must be replaced The foreign object can be found in the catalyst or in the particulate filter Back to back swap test with a new turbocharger After all the diagnostic, and if nothing wrong is found, it may be recommended to test with a new turbocharger and decide on turbo replacement.