Start up Guidelines

Thanks for your purchase of our new turbo or turbo core, please be aware that a blocked oil feed system are the number one cause of turbo failures. Please first investigate and remedy the cause of the previous turbo failure prior to taking the below steps. Please also check the condition of the BOV, EGR and DPF systems if fitted, these often work in parallel with the turbocharger and can cause turbocharger failure if not operating correctly.

Steps to proper turbo installation

 Start the turbo installation by removing old gasket material from the exhaust manifold and pipe. The surfaces of the flange must be clean and have no damage.
 Once the old turbo is removed, please check the rotation of the new turbo against the old, ensuring the exhaust and compressor housing, oil and water ports of the centre
section lines up identical, if not these can be adjusted at this time for a perfect fitment.
 Remove all plastic or foam blanking plugs from the turbo.
 Position the turbo onto manifold or engine block using the correct new gasket or O ring, and then reconnect the exhaust pipe.
 Tighten all nuts and bolts to the correct torque.
 Pay special attention to oil feed and drain lines, which must be totally clean and have no damage to ensure unrestricted oil flow.
 Make sure that no flexible hose liners have collapsed internally, and that oil feed line is
not too close to any source of heat which may have damaged the oil feed line internally.
This is common on some vehicles and difficult to detect without cutting the pipe! We
recommend fitting a new oil inlet pipe when installing the new turbo.
 Install oil drain line to the turbocharger, then pour new engine oil into the oil inlet hole of the turbocharger and fit the oil feed line. Spin the compressor wheel by hand a few times – it should spin freely. Note that it is normal to feel some up and down movement of the wheels. Install inlet and outlet air hoses to turbocharger compressor housing and make sure that the connection is airtight.

After the installation

 To test, crank the engine for 25 – 35 seconds to prime oil feed without starting the
engine.
 Start the engine and let it idle for 3 to 4 minutes to allow for proper inspection of oil, gas
and air leakage.
 If any leakage is detected during engine start up, please fix the issue immediately.
 For VNT turbos, please ensure that actuator operates correctly after starting up. During
vehicle key-on and start-up, it is normal for VNT turbos to show movement in actuator,
vane arm and vane mechanism, and it is also normal to hear a high-pitched noise from
electric actuators.
 If no movement is detected, please investigate the cause on the vehicle, as the actuator
operations has been set and tested before it left our factory.

Important Note: The gears in our electronic actuators are “self-blocking”, this means that it is not possible to move the actuator operating arm or the connecting rod manually. Attempting to move these parts with a tool or by hand may break the gears and make the turbo unusable. Damage of this sort is not covered by our warranty.

Finally, stop the engine and re-check engine oil level. It is important to make sure that oil level is between the minimum and maximum levels allowed.