Replacement Turbo Fitting Checklist

A replacement turbo needs a clean, working oil supply and the original fault sorted before it is started. Use this checklist alongside the instructions for your exact turbo and engine. The manufacturer's procedure takes priority.

Turbo replacement should be carried out by a suitably qualified workshop. A CHRA repair may also need specialist assembly and calibration equipment.

Before fitting

  • Identify and repair the cause of the previous failure.
  • Match the full part number. Compare housings, connections and actuator type before installation. If something differs, stop and check with us.
  • Check the intake, intercooler and exhaust for oil, debris and damage. Clean or replace affected parts as required by the manufacturer.
  • Check crankcase ventilation, oil pressure, oil feed and drain. Fit a new oil feed line where required or recommended for the application.
  • Have the correct new oil, filters, gaskets, seals and any specified single-use fasteners ready.

During installation

  • Keep all openings clean and covered until connection. Remove every transport plug before fitting the relevant line or pipe.
  • Clean and inspect mating surfaces. Use the correct gaskets and the specified tightening sequence and torque.
  • Keep sealant out of the oil passages. Use the sealing method specified for that connection.
  • Route oil and coolant lines correctly, without restrictions, kinks or contact with excessive heat. Connect coolant lines where required.
  • Follow the exact priming procedure before the first start, including the specified clean oil and method of establishing oil supply. Cranking time and how starting is disabled are vehicle-specific.
  • Only change actuator settings, stop screws, vane adjustments or housing orientation when the manufacturer's procedure specifically requires it, using the correct equipment. Never force an electronic actuator arm.

First start and final checks

Follow the manufacturer's initial idle and inspection procedure. Check oil, coolant, air and exhaust connections for leaks. Stop if there is a warning, abnormal noise or leak, and investigate before continuing.

Complete any required electronic adaptation or calibration. Recheck fluid levels as specified, then have the workshop confirm normal boost control and operation before returning the vehicle to service.

Keep the installation invoice, part numbers and service details. Contact us before fitting if the supplied part or instructions don't match the vehicle.

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