Turbo
Installation |
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The
following installation instructions are applicable to most makes
of turbo.
| Important
Notes |
|
- Failure
to follow these instructions (which are also supplied in print
with each turbo supplied) can lead to turbocharger damage and
may void warranty.
- Changing
the calibration of a wastegated turbo may damage
the turbo/engine and voids warranty.
 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.
- Refer
to engine/vehicle manufacturers literature for correct oil
type and quantity. Also, for torques and installation details.
- 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.
- 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 correct to specification.
- 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.
- Finally
please adhere to any 'special' fitting conditions ie replace
with manufactures modified parts, attached to your turbo unit.
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