GUIDE: Fitting a new turbocharger

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 turbo@carwood.org or call 01623 863600 for Sales, 01623 867996 for technical assistance.

www.carwood.co.uk