Latest News:

autotechnician - serving the independent workshop - logo

GUIDE: Fitting a new turbocharger

By autotech-nic on September 19, 2023

Before fitting a new turbocharger, it’s important to determine why the original failed & fix it, warns remanufacturer Carwood. If not, the replacement unit may fail too, costing you & your customer, more time & money, whilst also invalidating your warranty.

Prepare the engine & oil supply

• Drain the engine oil, fit a new OE quality oil filter (pre-filled with oil) & refill the sump to/with the recommended level & grade of oil.

• Check the air inlet ducting/manifold & air induction pipes for any debris, cracks or damage. Clean thoroughly & replace where necessary.

• Install a new OE quality air filter.

• Ensure the exhaust ducting/manifold, exhaust pipework, EGR & associated pipes are clean, clear & undamaged. Replace if necessary.

• Fit new OE quality oil feed & return pipes.

• Clean & prepare all gasket or joint surfaces – ensure faces are flat & not corroded.

Install the turbo

• Prime the turbo by injecting 10ml of the VM specified oil into the oil return outlet hole, using the syringe – you may have to turn it upside down to do this.

• Gently rotate the compressor wheel & shaft by hand for 30 seconds, while rocking it from side-to-side – the wheel should spin freely.

• Cover the hole with the sealing bung until ready to fit.

• Position the turbo, making sure the new oil feed & return pipes are correctly routed & primed.

• Fit new gaskets & o-rings, as required.

• Torque tighten the nuts & bolts securing the turbo to the exhaust manifold & exhaust gas outlet to VM settings.

• Fill the oil inlet hole with the correct engine oil & rotate the compressor wheel by hand again, for a minimum of 10 revolutions.

• Refit all turbo & boost pipework – ensure they are seated correctly & fasteners are in good condition.

Operate the vehicle

• Before starting, crank the engine continuously with fuel shut off for 10 – 15 seconds to build oil pressure.

• Start the engine & allow it to run at idle for 3-4 minutes before accelerating.

• Check for any air, oil or exhaust gas leaks – whistling, buzzing, ticking or vibration signals a problem.

• Drive the vehicle gently for the first 10 to 20 minutes so the oil can reach optimum operating temperature.

• It is also good practice to let the engine cool before switching off after a lengthy or high-speed journey.

For your safety

• Turbos can get very hot, so always allow it to cool down before touching.

• Keep hands, tools & material away from rotating parts when in use.

• Never remove the air intake pipe whilst in operation.

• Handle the unit with care – lift using the main housing only & not the actuator or pipes.

For more information, email or call 01623 863600 for Sales, 01623 867996 for technical assistance.



About Autotechnician
Autotechnician is a magazine published nine times a year, delivering essential information to independent garage owners and technicians in the UK. Delivered both digitally and in print, autotechnician provides readers with technical, training, business advice, product and news, allowing our readers to keep up to date with information they need to run and work within a modern workshop.
Aftermarket Media Solutions Ltd, The Joiners Shop, Historic Dockyard Chatham, Kent ME4 4TZ
T: 01634 816 165
Company no. 09625886
linkedin facebook pinterest youtube rss twitter instagram facebook-blank rss-blank linkedin-blank pinterest youtube twitter instagram