Turbo fitting guide

Fitting Guide

Always establish the cause of failure before fitting a replacement unit. The 6 most common failures are:

  • Oil starvation  
  • Oil contamination
  • Impact damage
  • Blocked Engine breather
  • Back pressure (blocked DPF/CAT/EGR)
  • Hot shut down

It is extremely important that you read the enclosed fitting instructions before fitting this  turbo. Failure to do so will result in premature failure and will be declined in the event of a warranty claim.

  1. Remove the engine sump and check oil pump, pick up strainer ,oil pump and all oil galleries for carbon contamination.
  2. If heavy carbon deposits are identified fit new oil pump, oil pump pick up  strainer and clean oil galleries
  3. Fit a new oil feed pipe, oil feed connectors and oil drain pipes and hoses.
  4. Remove the gauze filter that is in. the new banjo bolt that causes the pipe to block
  5. Remove oil cooler and oil filter assembly and clean thoroughly
  6. Remove intercooler, pipes and hoses remove residual oil
  7. Remove the vacuum pump and check for debris/carbon deposits and clean/replace as necessary.
  8. Remove the Rocker Cover/Cam Box clean all carbon and sludge deposits from the cover breather   ( where fitted) and associated valve gear.
  9. Check the Particulate Filter and cat are not blocked, replace if found to be heavily contaminated with oil from the failed turbo.
  10. Check all induction piping/air filter box and air filter are free from debris and that the turbine nut from the previous failure in not present
  11. Check engine breather and associated valves are working correctly and are free from debris.
  12. Check ECU to manufacturers specifications and all associated boost control valves/pipes for correct operation
  13. Check boost pressure does not exceed manufacturers limits
  14. Clean the Exhaust Gas Re-circulation Valve, induction manifold and all associated pipe work and ensure that the E.G.R.is functioning correctly.
  15. Do not use any type of sealer on any of the oil inlet and outlet connections to the turbocharger, also turbine inlet and outlet flanges
  16. Change oil and oil filter with correct type and grade of oil (refer to manufacturers specifications). It is very important not to overfill. (Modern engines are very slow fillers).
  17. Change engine oil filter after  200 miles and then every 3000/5000 miles
  18. Ensure that the particulate filter is regenerated frequently and is not blocked. At least one 50 mile continuous journey should be taken every month
  19. Check the fuel injector gaskets are not damaged, replace as necessary
  20. Where turbo oil feed pipe bolts to engine block, blow through engine block to clear debris from the failed turbo and carbon/sludge using a reputable cleaner before the oil pump is refitted
  21. Leave the oil feed pipe detached at the turbo end, crank the engine over without firing until  clean oil is flowing through from the pipe. It is convenient  to catch the oil in a plastic bag or container. When clean oil is flowing connect the pipe to the turbo
  22. Check oil flow:
  • Fit turbocharger , leave oil return pipe disconnected
  • Attach an extended oil return pipe and feed into a container
  • Start engine, idle for 60 seconds and switch off engine
  • Oil delivery should show at least 0.3 liters of oil
  • Repeat test to confirm flow is correct
  • Ensure during the test the engine is not run below minimum oil level

In some instances even after carrying out these  instructions not all of the carbon/sludge deposits will have been removed , resulting in turbo failure. In these instances  the turbo/cartridge will NOT be covers by the warranty as the failure is not due to a faulty component but failure due to external factors .