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Turbocharger Installation Instructions


(All items may not apply to your application.)



When installing a turbocharger, you must observe the following instructions:

  • Change oil and filter prior to turbocharger installation. Vehicles equipped with engine oil coolers, ensure oil cooler was flushed or replace after engine or turbo failure, as debris left in the cooler may reenter the engine and/or turbo and produce another consequent failure.
  • Install clean air filter and ensure entire intake system is clear of debris and foreign object. Proper air intake system with no external leaks is crucial.
  • Inspect and clean all turbocharger lines. This includes oil feed and return, as well as water feed and return, if applicable. Check oil lines for any restrictions, such as deposits, kinks, sharp bends, etc. If banjo bolts are used make sure they are clean of any restrictions. New oil lines are highly recommended with a new turbocharger installation.
  • All water and oil line connections must be utilized on the turbocharger as designed by the manufacturer. Using a water cooled and oil lubricated turbocharger without water cooling can result in premature failure, can be detected during turbocharger failure analysis, and WILL void the warranty.
  • Use new, high quality gasket at various turbo connections (oil, water, intake, exhaust). DO NOT use sealing compounds, such as RTV gasket-making silicone, at any oil connections.
  • Make sure oil return line is clean and free of any restrictions (kinks and/or sharp bends). Maintain a reasonable size drain tube diameter throughout the entire length of the turbocharger oil return line. Maintain a tube size diameter of 7/16” to ½” for most popular turbochargers, such as, but not limited to Garrett T2/T25/T28/T3/T4, IHI VF-series, Toyota CT-series, and MHI TD04/TD05/TD06. Turbo oil drain line must enter the engine above engine oil level. Turbo oil drain line should not tilt more than 20 degree from vertical in either direction. Excess tilting of the oil drain line can cause oil drain restriction and leakage at both compressor and turbine seals.
  • If angular orientation of the compressor and/or turbine housing is necessary, loosen the clamp plates and/or V-band clamps. After completing re-orientation, ensure mating flanges are tightly reseated and all fasteners retightened.
  • Re-orientation must be completed prior to making any rigid connections to the compressor and turbine inlets and outlets. Failure to do this will cause external stresses acting on the turbocharger unit and possible failure.
  • Do not install the CHRA (Center Housing Rotating Assembly) in a damaged compressor or turbine housing. Turbine housings cracked in the turbine wheel area may expand at operating temperatures and contact the turbine wheel, causing damage and/or complete turbocharger failure.
  • Turbocharger internal waste gate system, if applicable, must remain operable and MAY NOT be disconnected or modified.
  • Ensure engine breather system is clear and fully operational. Replacement of PCV (Positive Crankcase Ventilation) valve is highly recommended at the time of turbocharger replacement.
  • Ensure exhaust system is free of any restrictions which may cause excessive backpressure.
  • Ensure steady stream of oil flows from the turbo return line prior to starting the vehicle by cranking, but not firing, the vehicle and watching the disconnected turbo oil return line.
  • Start and idle the engine for three minutes after initial turbocharger installation.
  • Observe and maintain all oil and filter change intervals as advised by the vehicle manufacturer. Always idle the vehicle for at least 3 minute prior to shut down. Turbo timer installation is highly recommended to help maintain and extend turbocharger life.

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