Before you start:
- Make sure you know why the original turbo failed and rectified the fault. Remember, turbochargers are very reliable: less than 1% of turbos fail due to a manufacturing fault with the turbo itself.
- Your turbocharger technician can generally guide you in the right direction for possible causes from examination of the old components; see here...
- Some turbocharged vehicles suffer from “common faults”, such as blocked oil pipe or faulty EGR etc., please enquire if your vehicle suffers from a “common fault” which must be corrected for a successful installation.
- If your turbo has a wastegate or is a variable turbine turbo, it will be factory pre-set to suit your vehicle. Do not attempt to adjust it. This will compromise performance and invalidate the warranty.
Clean & check the air intake pipes and exhaust manifold
- Make sure they are free from contaminated and/or loose material, so no dirt or debris enters the turbo.
Clean, check or preferably replace if necessary the oil inlet and drain pipes are 100% clean and free from obstructions, internal carbon and/or sludge which is very common.
- A partially blocked pipe might infer no blockage however although there may be enough oil pressure, there may be not enough oil flow (volume) to adequately supply the turbocharger.
Replace the engine oil and filter, remembering to prime the filter.
- Use only OE standard parts and the oil specified by the engine manufacturer.
- Do not overfill.
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.
- Mount 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 hole with clean engine oil.
- Rotate the rotor assembly gently by hand, to ensure the oil lubricates 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.
- Connect all other external fittings to the turbo; do not use silastic etc. on oil feed or oil drain connections.
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 fault codes, or oil, air, exhaust gas or fuel leaks.
- The replacement turbo should now provide long and reliable service.