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Before installing replacement turbocharger it is important to fing the reason for the damage to previous turbo. If in doubt, contact your Distributor for advice.

TURBOCHARGER  INSTALLATION  INSTRUCTIONS

Before installing replacement turbocharger it is important to fing the reason for the damage to previous turbo. If in doubt, contact your Distributor for advice.

IMPORTANT NOTES:

1 Failure to follow these instructions can lead to turbocharger damage and may void warranty

2 Changing the calibration of wastegated turbo may damage the turbo / engine and voids warranty .

3 Correct gaskets must be used-they must not overlap holes.

❶. Gasket covering part of oil hole –reduces oil supply to turbo or if gasket material breaks away , may totally stop oil flow . ❷.Gasket clear of oil hole .Liquid gasket or sealants are not recommended , particularly for the oil flow .

sealants are not recommended , particularly for the oil flow .

4 Refer to engine /vchicle manufacturers litcrature for correct oil type and quantity .

Also,for correct torques and installation details .

5.Prevent dirt /debris from entering any part of the turbo during installation.

6.Before fitting the turbocharger ,check that the part number is the correct one for the

engine –fitting the incorrect turbo to an engine may damage the turbo /engine and

will void the warranty .

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.

▪REMOVE PLASTIC OR FOAM BLANKING PLUGS FROM THE TURBO BEFORE FITTING.

▪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 manifole 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 any flexible hose liners have not collapsed internally.

Check that oil feed line is not too close to source of heat .

❸Oil level OK,but drain line  damaged-causes oil leaks from turbo .

▪Fit air oil 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 4minutes 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 .

❹Oil level too high- blocks  oil drain from turbo –causes oil leaks from turbo .

❺Oil level correct to specification.

Check crankcase pressure .High pressure may be caused by piston bypass or blocked breather system .

❻High crankcase pressure can stop oil from draining-causes oil leaks from turbo .

 

 

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