Turbocharger Installation Instructions
It is important to conduct a diagnostic check of the engine system to determine if the “fault” is actually the turbocharger. A lack of power, noisy operation, excessive smoke or oil consumption could be caused by a faulty fuel injection system, electrical problems, restricted/blocked air filter, a damaged exhaust system, or a lubrication problem.
If possible, check crankcase pressure according to the engine manufacturer’s specifications. A higher than normal crankcase pressure reading may lead to oil leakage from the turbo into the inlet and exhaust systems.
Turbocharger damage can be a symptom of another problem so it is important to fix the problem before fitting a new turbocharger.
Common turbocharger problem areas to examine are:
- foreign objects
- lack of lubrication
- oil contamination
- over-speeding of the turbo and excessive temperature.
Before purchasing a new turbocharger check the part number to ensure that its the correct model for the engine. Installing an incorrect turbo could damage the turbo and will void the 12 warranty.
If in doubt, contact Speedup Autoparts and we will advise.
Turbo Installation Guide
- It is important that during the entire installation process, you prevent dirt or fragments from entering any part of the turbo. Any dirt or fragments entering the system may cause damage due to the high speeds the turbo spins at.
- Always ensure that correct gaskets are used. For example - the centre hole of any gasket must be perfectly aligned with the centre hole of the turbo flange. Some turbochargers use a threaded connector and no gasket. Other turbochargers use a “banjo fitting” with “banjo bolt”; in these cases, use new sealing gaskets/washers. Note: Do not use sealants, particularly for the oil inlet or outlet since excessive sealant has been known to enter the turbo, reducing or stopping the oil flow. Using sealants will void the warranty.
- The engine oil and oil filter should be replaced as per the vehicle manufacturer’s guidelines. Before fitting the turbo, ensure that all air hoses connected to the turbo are totally clean and show no sign of any damage. If they are damaged then they must be replaced.
- Check the air filter and its housing is totally clean and free from any debris. Also, we recommended installing a new air and fuel filter.
- Clean the engine Positive Crankcase Ventilation system (and ERG valve) to ensure that it's in full working order. Any blockages could cause high crankcase pressure and result in oil leakage from the turbo into the inlet and exhaust systems.
- Remove any old gasket material from the exhaust manifold and pipe. The surfaces of the flange must be clean and have no damage.
- Position the turbo onto manifold or engine block using the correct new gasket and then reconnect the exhaust pipe.
- Tighten all nuts and bolts.
- Check the oil feed and drain lines, as they must be totally clean and have no damage to ensure unrestricted oil flow. Make sure that any flexible hose lines have not collapsed internally and that the oil feed line is positioned next to sources of extreme heat as this can damage the oil feed line internally. To avoid oil contamination the turbocharger oil feed pipes and banjo bolts must be ultrasonically cleaned or replaced when installing the new turbocharger.
- Next, install oil drain line to the turbocharger.
- Pour new engine oil into the oil inlet hole of the turbocharger.
- Next, fit the oil feed line.
- Install inlet and outlet air hoses to turbocharger compressor housing. Make sure that the connections are airtight and hose clamps are correctly tightened.
- Crank the engine for around 10 seconds without starting the engine. If possible, disable the fuelling/ignition or use compression test mode to allow this. This will help to prime the oil feed to the turbocharger by filling the oil pressure lines, oil filter and turbo with oil before start-up. Note: Lubrication in these first few seconds of starting the engine is vital to the turbocharger. As soon as the engine starts, the turbo impeller cartridge will spin at high speed and a lack of lubrication can destroy the brand new turbo unit.
- Start the engine and let it idle for 3 to 4 minutes to allow for proper inspection for any oil, gas and air leakages. If any leakages are detected during engine start up, fix the issue immediately and repeat.
- Finally, stop the engine and re-check engine oil level. The oil level should be between the minimum and maximum mark on the dipstick. Note: It is important to make sure that oil level is not above the point where turbo oil drain pipe connects to the engine or this may lead to oil leakage from the turbo into the inlet and exhaust systems.