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Turbo Installation

The following installation instructions are applicable to most makes of turbo.

Important Notes

  1. Failure to follow these instructions (which are also supplied in print with each turbo supplied) can lead to turbocharger damage and may void warranty.
  2. Changing the calibration of a wastegated turbo may damage the turbo/engine and voids warranty.
  3. Correct gaskets must be used - they must not overlap holes. Gasket covering part of oil hole - reduces oil supply to turbo or if gasket material breaks away, may totally stop oil flow Correct gaskets must be used - they must not overlap holes. Gasket covering part of oil hole - reduces oil supply to turbo or if gasket material breaks away, may totally stop oil flow. Gasket clear of oil hole. Liquid gasket or sealants are not recommended, particularly for the oil inlet/outlet. Excess material may break away, reducing or stopping oil flow Gasket clear of oil hole. Liquid gasket or sealants are not recommended, particularly for the oil inlet/outlet. Excess material may break away, reducing or stopping oil flow.
Turbo Installation
  1. Refer to engine/vehicle manufacturers literature for correct oil type and quantity. Also, for torques and installation details.
  2. Prevent dirt/debris from entering any part of the turbo during installation.

Installing The Turbo

  • All air hoses connected to the turbo must be totally clean and undamaged.
  • Air filter and housing must be totally clean and free from debris.
  • Clean engine breather system and check function.
  • Remove old gasket material from the exhaust manifold and pipe. Faces must be undamaged.
  • Fill the oil inlet hole of the turbocharger with new engine oil and spin the compressor wheel by hand a few times - it should spin freely. Note: it is normal to feel some up and down movement on the wheels.
  • Fit turbocharger onto manifold or engine block (as applicable) using the correct new gasket or joint ring, then reconnect the exhaust pipe. Tighten all nuts/bolts.
  • Oil feed and drain lines must be totally clean and undamaged - oil flow must be unrestricted. Check that oil feed line is not too close to source of heat. Oil level OK, but drain line damaged - causes oil leaks from turbo Oil level OK, but drain line damaged - causes oil leaks from turbo.

Turbo Installation

  • Fit oil drain line. Refill the oil inlet hole with new clean engine oil and reconnect the oil feed line.
  • Fit air hoses and tighten.
  • Use new air, oil and fuel filters, refill engine with new engine oil.
  • If possible, prevent the engine from firing and crank the engine for 10-15 seconds to prime oil feed. Start the engine and idle for 3 to 4 minutes before increasing speed. Check for oil and gas/air leaks.
  • Stop engine and re-check engine oil level. Note: oil level should not be above the point where oil returns from the turbo to the engine.
  • Oil level too high - blocks oil drain from turbo - causes oil leaks from turbo Oil level too high - blocks oil drain from turbo - causes oil leaks from turbo.

Turbo Installation

  • Oil level correct to specification Oil level correct to specification.

Turbo Installation

  • Check crankcase pressure. High pressure may be caused by piston bypass or blocked breather system.
  • High crankcase pressure can stop oil from draining - causes oil leaks from turbo High crankcase pressure can stop oil from draining - causes oil leaks from turbo.

Turbo Installation

  • Finally please adhere to any 'special' fitting conditions ie replace with manufactures modified parts, attached to your turbo unit.

 




Turbo Developments Limited - Units 9-10 - Churchill House - 114 Windmill Road - Brentford - London - Middlesex - TW8 9NA
Tel: 020 8560 3927 - Fax: 020 8560 3928 - E-mail: turbodevelopment@btconnect.com

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