Fitting a New Turbo
When fitting a new turbo, you should always follow these steps: If you are not confident that you have noted and rectified all the secondary faults then call us…its what we are here for….
- Ascertain why the old unit failed. You don’t want the same problem to recur and damage the new unit. Miss the route cause and you,ll damage the new unit and warranty does not cover this !
- Ensure you are replacing like-for-like. The part number should be shown on the old turbo’s dataplate. The market is awash with sub standard parts. Get one of ours…if we are fitting them then they are good. Don’t think that cheap is the same as all units….remember Champagne tastes Lemonade pockets just makes things worse.
- Check for cleanliness. The smallest particles of dirt can do irrevocable damage to a turbocharger so check the engine intake/exhaust and intercooler cooler systems for cleanliness and obstructions, carefully removing oil, pieces of gasket, dust, dirt and other debris. Replace the air filter, oil filter and use the best quality oil you can..
Vehicle repairs - Check that the oil inlet and oil drain flanges are clean and free from obstruction, internal carbon and sludge, removing them to clean if necessary. If in doubt, replace with new.
- Replace the oil and filter, including the prime filter, ensuring that high quality parts and oil are used. Don’t skimp what ever you do ! Check the exhaust mounting flange is flat and free from cracks and carbon debris, and the studs are in good condition.
- Check that the manifold casting is not cracked on the outside or breaking up internally. If in doubt, replace with new.
- Check that the exhaust is blocked or is breaking up internally, blocked dpf filters, blocked catalytic convertors in many cases cause premature turbo failiure and if missed will immediately damage your new turbo. In many cases engine management lights do not come on so please ask us to check it for you !
- Check for boost leaks, very common and missed in many cases leading to turbo over speeding and premature turbo failiure.
- Check for injector “chuffing” which causes excessive sump pressure, poor oil return, excessive oil carbonisation and early turbo failiure.
- Mount the turbocharger on the exhaust flange, checking that the turbine inlet gasket fits correctly to give a gas tight seal.
- Align the end housings with all other connections and ensure that all fastenings are tightened to the specified torque. Check that any ‘O’ rings are not trapped when orientating the compressor cover as this may lead to a leakage.
- Connect the oil drain pipe, using the gaskets supplied. Do not use any liquid gasket product on turbocharger connections. BTN supplies a gasket set with every turbocharger.
- Fill the turbocharger oil feed hole with clean engine oil and rotate the rotor by hand before actually starteding the engine.
- Connect all external fittings to the turbocharger. On older engines, pull out the fuel stop and crank on the starter to develop oil pressure. On modern engines, start and idle for two minutes, checking that the oil warning light has gone out and that all air, gas, and oil connections are tight and free from leakage, using soapy water to help detect gas leaks. Tighten any fastenings as appropriate.
When fitting a new turbo, you should always follow these steps: If you are not confident that you have noted and rectified all the secondary faults then call us…its what we are here for….