Fitting Your Repaired or Reconditioned Turbocharger

Before fitting your turbocharger, please read the instructions below as failure to do so will void your guarantee. Prior to fitting a turbocharger, it’s useful to know why your original turbo failed. Most failures are due to:

  • Oil contamination or starvation
  • Air leaking over the speeding turbo
  • Impact damage
  • Electronic sensor failure
  • Blocked engine breather
  • Impurities entering the compressor housing
  • Hot shut down

Before you continue, are you fitting the right turbocharger? Never continue unless you are absolutely sure.

When you have identified the cause of the malfunction, it must either be rectified or the failed components replaced with new ones. Make sure you check the new turbo for any contamination. Before fitting your turbocharger from AC Turbos, you must replace ALL of the following components:

  • Air filter
  • Banjo bolts
  • Diesel Particulate Filter (DPF)
  • Gaskets and washers
  • New oil pump
  • O rings
  • Oil and oil filter (as per manufacturer’s recommendation)
  • Oil drain hose
  • Oil feed pipe

Make sure that your liquid level sensor is topped up with fluid. Following that, all of the following components need to be cleaned or replaced:

  • Air box and air intake hose
  • Breather system cam cover
  • Diesel injectors
  • E.G.R valve
  • Gaskets
  • Inlet/exhaust manifolds
  • Oil cooler/ intercooler/ hose

You’re almost ready to fit your turbo…
1. Check your oil pressure is within your manufacturer’s tolerances
2. Never use jointing compound on any part of your turbo
3. Make sure your turbo inlet is filled with oil and prime the turbo manually
4. Immobilise your engine and manually crank your engine until oil flows steadily from the oil feed hose Now you’re ready to fit and test your turbo.

After fitting your turbo, follow these instructions:
1. Crank engine until oil flows from turbo oil return pipe
2. Start engine and allow to idle for up to 5 minutes before driving
3. Check for any oil, air or gas leaks
4. Plug into diagnostic machine to decipher any error codes – must be rectified before road test
5. Check the boost pressure
6. Make sure you run another diagnostic check after 50/60 miles

If you have any questions or need help whilst fitting your new turbo, please do not hesitate to get in touch with us.