Important Turbocharger Fitment Instructions:
To ensure the longevity and proper functioning of your turbocharger, please follow the maintenance instructions listed below.
Failure to comply with these instructions will result in premature turbocharger failure and void the warranty.
Diagnose and Remediate the Cause of Failure: To prevent future failures, it is crucial to identify and address the underlying cause of the turbocharger failure. Ensure that a comprehensive diagnosis is conducted, and appropriate remedial action is taken before installing the replacement turbocharger.
- Perform Checks on the Following Components: (Prior to installation)
- Oil Supply: Check that the oil supply pipe is clean and free from obstructions; internal carbon and sludge (Replace if one of them are present) Conduct an oil pressure test (at the turbo supply) and keep proof of the test (Photo). If it’s not possible to do the test prior to installation, it should be done post installation on the first start-up.
- Oil Return Pipe: Inspect the oil return pipe for any blockages, leaks or restrictions.
- Air Intake System: Check the air intake system for foreign bodies (from old turbo) , leaks, restrictions, or damaged components.
- Exhaust System: Inspect the exhaust system for foreign bodies (from old turbo), leaks, restrictions, or damaged components.
- Clean/Repair the Following Components: Certain components require cleaning or repair to ensure optimal performance:
- Intake system: Send the intercooler to a radiator professional for thorough cleaning and pressure testing. Clean and inspect the boost pipes as well. Clean the complete intake system as well as the engine breather pipe that connects with the turbo air intake pipe.
- Catalytic Converter(s) & Exhaust Silencer Boxes: Remove, repair, or replace the catalytic converter(s) and exhaust silencer boxes if necessary.
- Replace/ fit the Following with a Turbocharger repair:
- Engine Oil: Replace the engine oil with the correct amount and grade as per the manufacturer’s specifications. Consider flushing the engine if necessary.
- Oil Filter: Install an OEM quality oil filter.
- Air Filter: Replace the air filter with a new OEM quality air filter.
- Pre-Oil the Turbocharger: Remove oil caps on the oil supply and return (if applicable) and pour new oil into the turbo center housing oil inlet for initial lubrication.
- ALL surrounding gaskets, copper washers & seals. DO NOT use gasket sealants or compounds!
- Fitment Procedure: (Use recommended torque specifications.)
- Install the turbocharger onto the engine, leave both oil pipes disconnected and crank (do not start) the engine until oil flows out from the turbo oil supply pipe (disconnect the fuel pump relay/ignition coil, etc., to prevent the engine from starting).
- Connect the turbo oil supply pipe.
- Crank the engine until oil flows from the turbo oil outlet.
- Connect the oil outlet pipe and crank the engine for 5 seconds; check and rectify oil level.
- Start the engine and let it idle for 5 minutes before accelerating.
- Perform Checks: (After to installation, engine off)
- Check for Leaks: Lubrication system, intake & exhaust system. (Consider doing a smoke test on the intake & exhaust system.)
- Conduct Engine Oil Pressure Test: Perform an engine oil pressure test on operating temperature and confirm that it falls within the engine manufacturer’s specifications. Keep proof of this test (Photo)
- Rectify any fault before starting / driving the vehicle.
- Before switching off the engine, let it idle for 3 to 4 minutes to allow the turbo internals to cool down properly.
Please ensure that you strictly adhere to these instructions to avoid voiding the warranty and experiencing premature turbocharger failure. If you have any further questions or require additional assistance, feel free to contact our customer support team.