Fitting Instructions – Turbocharger

Applies to all turbochargers supplied by Turboworks Turbochargers Ltd.

Failure to follow these instructions may result in turbocharger failure and invalidation of warranty.

IMPORTANT Warranty cover is conditional upon the turbocharger being fitted strictly in accordance with these instructions, accepted workshop practice, and the vehicle manufacturer’s requirements.

Turboworks Turbochargers Ltd reserves the right to reject any warranty claim where the turbocharger has suffered oil starvation, restricted lubrication, contaminated oil supply, installation-related damage, or repeat failure caused by unresolved engine or system faults.

Please retain receipts for all fitting components together with the completed warranty documentation, as these may be required in support of any warranty claim.

Before Fitting the Turbocharger

Before installing the replacement turbocharger, the fault that caused the original unit to fail must be correctly identified and fully rectified. Failure to eliminate the original cause of failure may result in immediate or premature failure of the replacement unit, which is not covered under warranty.

The following checks and procedures must be completed before installation:

Check that the engine exhaust system, intake system, intercooler, boost hoses, airbox, and all related pipework are clean, undamaged, and completely free from oil residue, gasket fragments, dust, dirt, carbon deposits, and any foreign objects, including debris from the failed turbocharger. Any damaged or contaminated components must be replaced.
To prevent contamination of the replacement turbocharger, the oil feed pipe must be replaced irrespective of its apparent condition.
Replace the engine oil, oil filter, and air filter using components and lubricants of the specification required by the vehicle manufacturer.
Inspect the turbocharger oil drain pipe for kinks, internal carbon build-up, restrictions, or physical damage. If there is any doubt as to its condition, it must be replaced.
Remove and inspect the crankcase breather hoses and filters. Clean or renew these components in accordance with the vehicle manufacturer’s service recommendations.
Immobilise the engine. Using a clean container to catch the oil, crank the engine until at least 300ml (approximately 1/2 pint) of oil has been pumped through the turbocharger oil feed line. This is necessary to flush out dirt, carbon particles, sludge, or other contamination that may otherwise damage the bearings of the replacement turbocharger.
On known problem applications, inspect associated lubrication components in accordance with best workshop practice. On Peugeot / Citroën / Mazda / Volvo 1.6 Diesel applications, the oil pump must be replaced.

DO NOT

Reuse the original oil feed pipe
Install without flushing the oil system
Allow contamination to enter oil or air passages
Use sealants unless specified by manufacturer
Operate the engine under load before checks are completed

Installation Procedure

The turbocharger must be installed in clean workshop conditions using correct fitting procedures at all times.

Ensure absolute cleanliness during installation. Dirt, lint, gasket material, carbon particles, sealant, or debris must not be allowed to enter any oil or air passage.
Do not remove the oil feed blanking plug until the turbocharger is ready to be fitted.
Do not use exhaust sealing paste or other sealing compounds unless expressly specified by the vehicle manufacturer.
Connect the new oil feed pipe only after all flushing and preparation work described above has been completed. Care must be taken to ensure that no contamination enters the turbocharger bearing housing during installation.
Before fitting the oil drain pipe, check that any blanking plug fitted to the turbocharger has been removed where applicable, then crank the engine until oil flows from the turbocharger bearing housing. This confirms that the turbocharger is receiving oil correctly before final assembly.
Refit the oil drain pipe and ensure it is correctly aligned, unrestricted, and securely fitted.
Check that all oil, air, exhaust, vacuum, coolant, and control connections are correctly positioned and tightened to the required specification. Do not overtighten fixings or unions.

Post-Installation Checks

Once installation is complete, the following checks must be carried out:

Start the engine and allow it to idle.
Check carefully for oil leaks, boost leaks, exhaust leaks, unusual noises, vibration, or any signs of restricted oil return.
Confirm that the lubrication system is functioning correctly and that oil is flowing and draining as intended.
Using suitable diagnostic equipment or a boost gauge where applicable, check that boost pressure remains within the vehicle manufacturer’s specified limits.

The vehicle must not be subjected to load or full boost operation until correct oil supply, sealing, and turbocharger operation have been confirmed.

These fitting instructions form part of the warranty conditions. Failure to follow the above procedures may result in rejection of any warranty claim.