1 BEFORE REPLACING A TURBO
A thorough diagnostic check of the engine system is essential to determine if the turbocharger is at fault, as symptoms like power loss, noisy operation, excessive smoke, or oil consumption may arise from issues with the fuel injection system, ECU, electrical components, air filter, exhaust system, or lubrication, and elevated crankcase pressure could indicate oil leakage from the turbo into the inlet and exhaust systems.
2 BEFORE REPLACING A TURBO
If the engine diagnostic check reveals no clear cause, ensure a comprehensive troubleshooting analysis is conducted, focusing on key turbocharger areas such as foreign objects, lubrication issues, oil contamination, turbo over-speeding, and excessive temperatures, as turbo damage may indicate an underlying problem rather than being the root cause.
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The following steps must be strictly adhered to: always refer to the workshop manual for instructions specific to your engine or vehicle.
Verify the part number to ensure it matches the engine specifications, as installing the wrong turbocharger can damage both the turbo and the engine, voiding the warranty.
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During the entire installation process, it is crucial to prevent dirt or debris from entering any part of the turbo, as contamination can lead to catastrophic damage due to the turbo's high operational speeds of up to 300,000 RPM.
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Ensure that the correct gaskets are used, with the center hole of each gasket perfectly aligned with the center hole of the turbo flange. Some turbos may utilize a threaded connector without a gasket, while others may require a "banjo fitting" with a "banjo bolt," necessitating new sealing gaskets or washers. Avoid using liquid gasket or sealants, especially for the oil inlet or outlet, as excessive material can enter the turbo and impede or block oil flow.
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It is advisable to use new air, oil, and fuel filters, along with clean engine oil that meets the vehicle manufacturer's specifications. When installing the new oil filter, if possible, fill it with clean, fresh engine oil. Additionally, if accessible, back-fill the pressure line from the oil pump to the filter, which is especially important for high-mileage engines where the oil pressure line may empty during oil changes.
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Before installing the turbo, ensure that all air hoses connected to it are completely clean and free of any damage. Inspect all electrical connections and harnesses for any breaks or damage, paying particular attention to the electrical pins inside the plugs. Poor or improper connections can lead to damage to the turbocharger or engine, so replace any damaged electrical connectors with new genuine OE parts.
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The air filter and its housing must be thoroughly clean and free from any debris.
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Clean the engine breather system (Positive Crankcase Ventilation system) and ensure it is functioning properly, as any blockages or malfunctions can result in high crankcase pressure, leading to oil leakage from the turbo into the inlet and exhaust systems.
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Remove any old gasket material from the exhaust manifold and pipe, ensuring that the flange surfaces are clean and undamaged. Additionally, take out any plastic or foam blanking plugs from the turbo.
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Position the turbo onto the manifold or engine block using the correct new gasket or O-ring, then reconnect the exhaust pipe. Finally, tighten all nuts and bolts securely.
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Pay special attention to the oil feed and drain lines, ensuring they are completely clean and free from damage to allow unrestricted oil flow. Check that flexible hose liners have not collapsed internally and confirm that the oil feed line is not positioned too close to heat sources, which could damage it internally—this issue is common in some vehicles and may be difficult to detect without cutting the pipe. For this reason, it is recommended to install a new oil inlet pipe when fitting the new turbo.
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Before installing the oil feed connection/line, use a dedicated Turbo PreLube by squeezing the entire 20ml into the oil inlet hole of the turbocharger.
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Next, install the new oil feed line.
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Install the inlet and outlet air hoses to the turbocharger compressor housing, ensuring that the connections are airtight and the hose clamps are properly tightened. If there are concerns about air leaks, perform an engine smoke test to identify any issues. If leaks are detected, repair or replace the affected components, as these leaks can impact the performance of both the turbocharger and the engine.
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Crank the engine for 10 to 15 seconds without starting it. If possible, disable the fueling/ignition or use compression test mode to facilitate this process. This action helps prime the oil feed to the turbocharger by filling the oil pressure lines, oil filter, and turbo with oil before startup.
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Then, start the engine and let it idle for 3 to 4 minutes to properly inspect for oil, gas, and air leaks. If any leakage is detected during startup, address the issue immediately.
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Stop the engine and recheck the engine oil level. The oil level should be between the minimum and maximum marks on the dipstick. It is crucial to ensure that the oil level is not above the point where the turbo oil drain pipe connects to the engine, as this may lead to oil leakage from the turbo into the inlet and exhaust systems.
