Correct installation is the key to ensuring your new Turbo doesn't give problems in the future.
First things first...... Why did the original Turbo unit fail?? Did you know that over 90% of Turbocharger failures are caused due to outside influence? This can be oil contamination, oil starvation, incorrect Turbo boost pressure, foreign object damage, as well as blocked engine breathers, cats and diesel particle filters. Before fitting a new Turbo unit, you MUST find the cause of the original failure and correct it before fitting the new unit.
Installing a new Turbo.
Ok, before removing the turbo, we advise you let the engine idle to operating temperature before switching off and draining the engine oil from the sump (be VERY careful as oil will be HOT) As the oil is more fluid when warm, you have a greater chance of removing as much as possible. NOTE: If the Turbocharger has completely failed and oil if found in boost pipe work, this point must NOT be undertaken.
Next, refit the sump plug and fill sump with a high quality engine flush and following the instructions on the container, flush the engine before again removing the sump plug and draining completely.
Now remove the oil filter and dispose of. Remove the old Turbocharger as well as ALL oil and Turbo boost pipe work.
Check all Turbo boost pipe work for splits, holes or damage and ensure oil and dirt is removed. If damaged replace.
Remove Turbo intercooler (if fitted) and flush with an oil degreaser before leaving to drain completely.
Remove Air filter and dispose of before checking air box for damage. Clean and fit new filter element.
Check EGR where fitted to ensure correct operation is seen, clean/replace as required.
Upon fitting new Turbocharger, ensure all Turbo gaskets are replaced where required and that all bolts and nuts are tightened to manufacturer settings.
Refit Turbo intercooler and all Turbocharger boost hoses ensuring seating correctly and fasteners are in a good condition.
Once Turbo and all boost pipe work is refitted and checked, fit a NEW Turbo oil feed pipe. This MUST be a GENUINE OE replacement, the reason for this is Turbo oil feed pipes are often revised in design to overcome past issues. Before connecting the Turbo oil feed pipe to the Turbo itself, squirt some engine oil into the turbo oil inlet to ensure the Turbo doesn't run dry on start-up.
Once oil feed pipe is connected, a visual check is required on everything you have done to ensure all parts are connected correctly and securely.
Fit a NEW oil filter and a refill sump with correct grade of oil. If possible, fill oil filter with oil prior to fitting to ensure a delay in oil supply to the Turbo isnt found as the filter and lines fill on 1st start.
If possible, crank engine without starting for 5 second intervals allowing a break in between for the starter to cool. Otherwise, start the vehicle WITHOUT revving the engine.
Allow engine to idle until up to operating temperature and then switch off. Check oil level is correct and check for any leaks.
On first drive, drive vehicle gently allowing Turbo to spool up gradually without accelerating fully.
This completes initial installation. We advise an oil and oil filter change after 100 miles and then further servicing as per the manufacturer guidelines.
If you are unsure in any way about fitting your new Turbocharger, please contact us.