Turbocharger Installation Instructions

IMPORTANT: Failure to follow these instructions, improper use of the turbocharger, or modifications to it can cause damage to the turbocharger and engine, resulting in the loss of the warranty. Most turbocharger failures are caused by factors external to the turbocharger itself. Following these instructions is essential for its proper functioning and prolonging its life.

Remember that the warranty only covers the replacement or repair of the turbocharger and never covers installation, towing, or other expenses that may arise.

Before Assembling:

  • Inspect the engine: If the turbine rotor is damaged, inspect the exhaust manifold to ensure it is not disintegrating. Even very small fragments can cause serious damage to the rotor. Check the intake manifold fins, glow plugs, and intake components for breakage.
  • Check oil system: If bearings have excessive play, it may be due to insufficient or poor-quality oil. The oil and filter must be replaced. Replace the turbocharger oil inlet pipe to ensure proper lubrication.
  • Check for leaks/obstructions: If oil leaks occur, check crankcase vent holes and the oil separator. Oil accumulation in the intercooler can cause the engine to run faster than normal; clean it properly.
  • Air Filter: Use extreme caution when replacing the air filter. Any object introduced could strike the compressor rotor, causing serious damage. 

Assembly:

  1. Verify that the engine intake/exhaust systems and the intercooler are clean and free of obstructions. Replace the air filter if necessary.
  2. Verify that the oil intake and exhaust flanges are clean. CAUTION: Never use any type of sealant on the gaskets.
  3. Replace the oil and filter using manufacturer-specified parts.
  4. Mount the turbocharger onto the exhaust flange, ensuring the turbine intake gasket fits properly.
  5. Connect the oil drain hose, then fill the turbocharger oil feed hole with clean engine oil and slowly rotate the rotor by hand.
  6. Connect all external connections. Remove the fuel cap and start the engine to increase oil pressure. 

After Assembly:

  • Priming: Before starting the engine, crank it briefly (without starting) to circulate oil in the turbocharger. You can verify oil flow by disconnecting the exhaust pipe from the crankcase briefly.
  • First Run: Start the engine and let it idle. Check for leaks in air, fuel, and oil connections. Use soapy water to check for gas leaks.
  • Check Compression: Ensure engine compression is correct; insufficient compression will cause oil leaks in the turbocharger.
  • Warm-up/Cool-down: Avoid sudden acceleration until oil temperature stabilizes. Let the engine idle for one minute before stopping the vehicle after prolonged use. 

Common Causes of Turbo Failures

Turbocharger failures are often caused by external factors such as:

  • Foreign Objects: Ingestion of objects through the intake or exhaust manifold which impacts the compressor wheel or turbine shaft, unbalancing the rotor.
  • Lack of Lubrication: Fatigue failure or material transfer caused by metal-to-metal friction due to insufficient oil supply, improper gasket seating, use of liquid gaskets (sealants), or poor-quality lubricants.
  • Oil Contamination: Damage to the bearing system due to carbon particles (from infrequent oil changes) or metal fragments suspended in the oil.
  • Excessive Speed or Temperature: Operation beyond design limits, engine malfunctions, or unauthorized performance modifications can cause fatigue failure of the wheels and turbine.

Diagnosis Note: If the engine isn’t running properly, don’t assume the turbocharger is the cause. Check engine compression first. Turbochargers in good condition are often replaced when the problem is internal to the engine.