KLR turbo manifold failure

[Summiitt]

Hi all.
Anyone had issues with their KLR turbo kits? Im onto my second turbo in around 5000k and now the manifold has around 6 cracks in it..
My 6x6 is a work vehicle , loaded to 5500GVM and run 6 days per week.The motor has some wear due to an air cleaner issue, Apon removal and inspection its also found that the turbo and manifold is stuffed. We are now wondering if the majority of the issue is with the turbo upgrade as the motor was fitted only 40k ago.. I don't want to question the quality of the KLR product but I'm pretty ****ed on the lack of reliability with the upgrade.. looking for feedback.
Cheers

[tc_s1]

I did have a KLR turbo on one of my Perentie Cargos go out at less than 10k kms. Sent it back and they shipped another to me and then did an analysis on it. Theu said it looked like it was stsrved of oil, but I installed the second unit exactly the same and have had no issues to date, a year+ later. KLR provided outstanding support and service, so if there is any quality issue you have encountered I'd hope you would find a similar experience to mine.

[Vern]

Have heard of this a bit before, particularly the turbo. Do you still have the factory log manifold laying about, if so, put that back on. To be honest, I am not really sure why people with a T motor, go down this path, just fit a better turbo and tune to suit.

[Red90]

What are your EGTs? Sounds like you are running too hot.

[Summiitt]

Have heard of this a bit before, particularly the turbo. Do you still have the factory log manifold laying about, if so, put that back on. To be honest, I am not really sure why people with a T motor, go down this path, just fit a better turbo and tune to suit.
?? Thats why I went down this path, it was supposedly a better turbo and manifold set up, with a slight pump tune

[Vern]

?? Thats why I went down this path, it was supposedly a better turbo and manifold set up, with a slight pump tuneOver $3k better? I don't think so.
The factory non wastegated turbo isn't much chop, but the factory wastegated one work well, as do many other turbos. Much better options than the turbo they run, but each to their own

[Summiitt]

Its 3k better in performance given what we do with them, but if its not reliable then I agree, there must be better options. Whats the wastegate one your referring to?

[Vern]

What I meant, was you could have put a $900 turbo on, and got the same or better gains than the set up you chose.
For example, my mate put the klr kit on his perentie, I used a factory manifold and td04 turbo, similar tunes, I made 6kw more on the dyno than him, my set up cost $1300.
Garret tb2568 is the wastegated one. I believe klr uses the garret gt2252

[Red90]

Sure but you need to custom build the plumbing, oil lines, crankcase ventilation system, get a manifold, custom build an adapter to the turbo, build the exhaust. Cheaper but requires a lot of work. It is too bad someone does not do a full kit with a cheaper manifold and a larger turbo.

[Summiitt]

So I posted this thread late April, (Turbo and manifold failure) my 6x6 is still off the road and KLR have gone into lockdown, they have offered a refund of the kit, however, with the fitting and exhaust works Im out of pocket about $2k, let alone the cost of having the vehicle off the road. It is a support ute to forestry equipment, the inconvenience and cost in having this vehicle off the road cannot be put into $$ terms. To get it back on the road, I still need a factory manifold and connection to the exhaust system. Ive purchased items off KLR in the past for my 2 6x6s and have been happy with them, however, this experience has left me dumb founded.
It is clear that these turbo upgrades are only suitable for partly used, lightly loaded city based perenties, that never really work, they are obviously poorly designed and constructed manifolds (my last had 7 cracks after only 2200km). Save your money people if you rely on your perentie to earn a living,2 turbos in 5,000km isn't acceptable.
Im so disappointed that they won't even pick up the phone and try and sort through the issues, as I don't think Im being unreasonable..Just after some reliability that has so far been missing..

[p38arover]

Two turbos in 5,000km sounds like there is some other underlying problem.

[Phil B]

Sustained very high EGT’s would do that I would have thought.
Only my opinion.

[Vern]

Two turbos in 5,000km sounds like there is some other underlying problem.Underlying issue isn't with the vehicle, this has happened to quite a few 4bd1 folk out there.

[p38arover]

Underlying issue isn't with the vehicle, this has happened to quite a few 4bd1 folk out there.

You have proof of this?

[Vern]

You have proof of this?Quite a few different people have bought this up on the Facebook pages. Feel free to go and have a search. From cracked manifolds, dead turbos, and cracked exhausts.

[Phil B]

Could this just be a case of owners chasing “just that little bit” more power by unscrewing the fuel screw causing excessive EGT’s, burning turbos and doing other damage?
The trouble with the Isuzu is that it is too easy to increase the fuel and do damage with just one spanner if you don’t monitor EGT’s.
KLR cannot control this “tweaking”.
The Garrett is a good quality turbo used on millions of engines. Why else would they now be failing in such allegedly large numbers?

Shout at me if you like but it is a fact that consumers are often to blame for “faulty” goods they buy, and not only turbos.
I have no ties to KLR other than they have always done the right thing to me. And yes I do have a KLR turbo kit which has performed faultlessly for over 30k km since new when I put it on. There again I run a conservative tune and watch my EGT’s like a hawk.

My opinion only.

[Vern]

I don't have the fuel screw in my T motor at all, my egt's don't get high enough to cause damage. One would think the high egt's would damage the motor before the turbo let alone the manifold.
Mine is intercooled though, but I do remember talking to brad ages ago and they concluded they didn't need intercooling. I also remember trying this with rovercare years ago and found the same. Guessing that also all depends on how you load up the vehicle.

[Summiitt]

Could this just be a case of owners chasing “just that little bit” more power by unscrewing the fuel screw causing excessive EGT’s, burning turbos and doing other damage?
The trouble with the Isuzu is that it is too easy to increase the fuel and do damage with just one spanner if you don’t monitor EGT’s.
KLR cannot control this “tweaking”.
The Garrett is a good quality turbo used on millions of engines. Why else would they now be failing in such allegedly large numbers?

Shout at me if you like but it is a fact that consumers are often to blame for “faulty” goods they buy, and not only turbos.
I have no ties to KLR other than they have always done the right thing to me. And yes I do have a KLR turbo kit which has performed faultlessly for over 30k km since new when I put it on. There again I run a conservative tune and watch my EGT’s like a hawk.

My opinion only.

The first turbo cooked itself from overspinning. We couldn't keep the flexible intake hoses on the unit, KLR were good and after the unit was sent away to be inspected, they supplied us with a new turbo. Everything was checked and double checked in the installation which was carried out by a LandRover specialist. Every measurement and adjustment was recorded and double checked against KLRs specs. We are not new in how to run a Diesel engine with respect to EGT and running them for reliability when they are working hard..this kit is simply not up to the task.
Yes, we are trying to get some more power out of the 6x6..thats what the kit is marketed as, if its not up to it then back to the drawing board. Im just lucky that I had a backup ute that could carry all the equipment for the 3 months that this has gone on for.

[Phil B]

Vern
I know you personally monitor EGT’s. You have said so in previous posts. I am saying that possibly others don’t. Many don’t even have EGT gauges.
I am in no way an expert but in my simple mind if the exhaust gases are overheated (say 750 deg plus) the first things they would heat up are the manifold and turbo which is possibly why they are failing if this condition is sustained over and over again.
Yes the engine would also fail eventually but maybe the manifold and turbo are acting as a “weakest link” in the chain?
I don’t profess to know enough about this to say that it is the problem but it is certainly a possibility IMO.
Regards,

[Phil B]

The first turbo cooked itself from overspinning. We couldn't keep the flexible intake hoses on the unit, KLR were good and after the unit was sent away to be inspected, they supplied us with a new turbo. Everything was checked and double checked in the installation which was carried out by a LandRover specialist. Every measurement and adjustment was recorded and double checked against KLRs specs. We are not new in how to run a Diesel engine with respect to EGT and running them for reliability when they are working hard..this kit is simply not up to the task.
Yes, we are trying to get some more power out of the 6x6..thats what the kit is marketed as, if its not up to it then back to the drawing board. Im just lucky that I had a backup ute that could carry all the equipment for the 3 months that this has gone on for.

Summit
Please don’t get me wrong I am not trying to divert responsibility away from KLR. If they supply a product that fails they should ( and have in your case) replace the faulty product.
All I am saying is that their maybe another reason outside of their control that is causing the failures.
IMO the heat generated by sustained full power operation could be that reason.
The only way to know is to monitor the levels of that heat with an EGT gauge and alarm.
If it helps even my moderate tune will generate EGT’s of over 600 deg post turbo if I leave the loud pedal planted up very steep hills with a trailer behind me. When it does my alarm goes off and I let go. It cools immediately when I do.
I hope this helps
Phil

[p38arover]

Quite a few different people have bought this up on the Facebook pages. Feel free to go and have a search. From cracked manifolds, dead turbos, and cracked exhausts.

I don't do Facebook and would have no idea how to search it. On the odd occasion I've wanted to look at something, FB wouldn't let me in because I hadn't logged in.