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7. Modifications to eliminate OEM Design faults on petrol and diesel turbo engines.

With the ever increasing complexity and cost of modern engines and the items externally attached to them a number of expensive failures are occurring which are not normal wear and tear and often are not fixed under warranty by the manufacturer.
These failures can be very expensive and can repeat fail unless modifications are made to eliminate the cause of the failure.
The most notorious of this type of problem is the turbo and/or engine self destruction problem in the ZD30T Diesel engines in Patrols and Navaras.  Ford also has a problem with turbo failures in the BA Falcon.
These are common examples of not normal wear and tear damage but original design faults which can be eliminated by modification of the components and functions which cause the failures.
When we see a problem of this type commonly recurring, a modification process is developed to eliminate the cause of the failure which can be applied to vehicles before the problem occurs and therefore save customers the agony of a major failure usually a long way from home.  Modern diesel engines can cost up to $20,000 to replace which makes a low cost prevention very good value.
In the case of the ZD30T engine and turbo failures in Patrols, the ineffective control of boost pressure, non-effective inter cooling, exhaust gas entering the inlet manifold and combustion process, non existent overboost protection and high exhaust manifold back pressure all combine to create piston crown overheating failure and extreme turbo shaft speed creating bearing failure in the turbocharger.
With the turbo compressor and shaft failure with shrapnel damage to the engine internals problems in the ZD30T Navaras, a sub-standard and failure prone poor quality original turbocharger is the prime cause of repeat failures from as low as 60,000km.
Both of these abnormal problems can be prevented by suitable modifications applied before a major failure occurs.
The BA Falcon turbo bearing failure is simply oil starvation to the turbo which is easily prevented by plumbing and service changes.  In extreme applications coolant plumbing also needs to be modified. 
Design fault problems are not eliminated by simply replacing damaged parts.  Modifications are also needed to prevent repeat failures.