Before you start fitting your turbo make sure you know why the original turbo failed in the first place and rectify the fault. Remember, turbochargers are very reliable; less than 1% of turbos fail due to a malfunctioning fault with the turbo.
Some turbos come with critical fitting instructions, such as oil pipe replacement, which must be followed for a successful installation, failure to follow these instructions could invalidate the warranty.
If your turbo has a wastegate or is a variable turbine turbo, it will be factory reset to suit your vehicle, do not attempt to adjust it as this will compromise the performance and invalidate the warranty.
The turbo is an internal part of the air, fuel, cooling and oil systems, so ensure they are all working correctly with the right fluid levels and no leaks or blockages, replacing any failed or suspect parts with OE parts.
- Check the air intake pipes and exhaust manifold to make sure they are free from contaminated and loose material, so no dirt or debris enters the turbo.
- Check the oil inlet and drain pipe are clean and free from obstructions, internal carbon and sludge. clean or replace if necessary. replace the engine oil specified by the engine manufacturer and prime the filter.
- Check the exhaust mounting flange is flat and free from cracks and carbon debris, and the studs are in good condition. check the manifold casting is not cracked on the outside or breaking up internally. if in doubt, replace. mount the the turbo on the exhaust flange, checking the turbine gasket fits correctly to give a gas tight seal.
- Connect the oil drain pipe. prime the turbo by filling the oil feed port with clean engine oil. rotate the rotar assembly by hand, to ensure the oil protects the bearings. connect the oil feed pipe to the turbo. lack of oil priming during fitting, and incorrect starting procedure, can cause premature turbo failure.
- Make sure the engine oil circulates and the turbo is thoroughly lubricated before it operates under load. disconnect the ignition system or fuel supply, so the engine turns over without firing up. check the oil pressure warning light goes out. reconnect the ignition or fuel supply and start the engine. run it at a fast idle while you check there are no diagnostic faults or oil, air, exhaust gas or fuel leaks
- Test drive the vehicle.
- … and that’s all there is to it!