Turbocharger installation guide

The following requirements and guidelines need to be carefully met. An incorrectly mounted turbocharger on the engine may be damaged and may not be warranted. Failure to comply with these requirements will result in a loss of time for both the owner and service carers, so we encourage you to read the instructions carefully before starting work, and if you have any questions, consult a professionalsor contact us.
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TurboSystems seeks to ensure that turbochargers work perfectly, so we consult car services free of charge on how to professionally install turbochargers.

GENERAL REQUIREMENTS:

  • Inspect the turbocharger inlet and outlet systems;
  • make sure there are no extraneous elements and sealing intermediate residues;
  • Take into account that at high speeds, small parts fallen in the turbocharger can cause severe damage to the rotor;
  • Make sure that all protection caps are removed from the turbocharger;

When installing a turbocharger on the engine, make sure dirt and foreign objects would get in to turbocharger inside. ​

When the engine is fitted with a new or repaired turbocharger, engine oil and oil filter must be replaced. We recommend checking the air filter and, if necessary, replacing it. Use lubricants for turbo-blower engines.

Use the new and tested gaskets to seal the air system and connect the exhaust system to the turbocharger. USE OF SEALING COMPOUNDS (HERMIC) FOR LUBRICATING SYSTEM CHANNELS ARE PROHIBITED. Check the engine oil drain line and drainage pipes so that they are not damaged, deformed or they do not have narrowing and there are no other suspicious signs. If in doubt, change these parts. In some cases it is necessary to replace the tubes. ​

When the turbocharger is mounted back on the engine, it is prohibited to use the sealant turbocharger inlet and outlet flange. All turbocharger bolts (nuts) must be tighten with the strenght specified in the engine’s technical documentation.

Before connecting the lubrication inlet tube, fill the turbocharger oil drain hole with clean engine oil and turn the compressor wheel a few times to allow oil to enter bearings.

Before connecting the lubrication outlet tube (hose), launch the engine until a constant flow of oil from the drainage channel of the turbocharger appears. This avoids dry friction in the turbocharger during engine startup.

Before starting the engine, it is necessary to disconnect the fuel supply and crank the engine up to 20-30 s in order to fill the lubrication system. ​

When the turbocharger is already fully assembled and connected, allow the engine to idle for at least 3 minutes. It protects the turbocharger bearings from damage and removes remaining dirt from the lubrication system and bearing housing. ​

Check for lubricating oil, coolant, exhaust gas and air leaks.

If the repair was done for the engine or overhaul was done oil and oil filter must be changed after 100 km of using after installing new turbocharger. Another oil change should be done after 1000 km. ​

In all cases, when a turbocharger repair is done or new turbocharger is installed, it is necessary to replace the catalyst or remove it. Clogged up catalytic converters will prevent the gas from flowing freely to the exhaust system. The pressure builds up between the turbocharger and the catalyst, which further presses the exhaust pulley and damages the turbocharger. ​

It is prohibited to use an engine rinse aid. ​

WARNINGS:

  • It is strictly forbidden to turn the turbocharger shaft without lubrication;
  • It is forbidden to close the air supply to the turbocharger when engine is running, as this will damage the turbocharger.

REQUIREMENTS FOR OPERATION:

  • Do not stop the engine immediately after work in heavy duty (after loads).
  • Before turning off the engine, depending on the load, it is necessary to leave engine on idle for 20-120 seconds;
  • Avoid hard accelerations when engine is cold;
  • Do not operate the engine without an air filter, as turbocharger blades may be damaged;
  • It is prohibited to operate the engine when the oil level is below the permissible limit;
  • It is necessary to change the engine oil and oil filter according to engine specifications
  • The lubricating oil quality and the oil filter must match the specified vehicle and engine;
  • Make sure the exhaust system is not clogging up (especially for cars with catalytic converters). Blocked exhaust system or catalyst may damage turbocharger.