Installation Instructions

CAUTION: Your turbocharger will fail again if you do not follow these instructions.

Inspection

1. Check both compressor & turbine housings for wheel rub damage, corroded or stripped threads in mounting holes, & damage to the mating surfaces with the cartridge/chra. Replace/re-work as required. Remove any gasket material on the exhaust manifold mounting flange & oil inlet flange. If any of these conditions apply, reduced performance, extensive damage & premature failure may occur.
2. Remove any foreign material/dirt in the air cleaner & ducting to the compressor inlet, & in the exhaust manifold/turbine inlet. Any foreign object may cause reduced performance, extensive damage & premature failure may occur.
3. Check oil drain & supply lines for kinking, clogging, restrictions or any other deterioration & replace as necessary. It is recommended that these lines are replaced.

Installation & Pre-Oiling

1. Using new gaskets/O rings, install the turbocharger on the engine without connecting the compressor inlet & oil supply line. Secure the nuts/bolts attaching the turbocharger to the exhaust manifold using the manufacturers’ recommended settings. A high temperature lubricant is recommended on the threads. Sealing & jointing compounds are not recommended.
2. Disable the ignition & crank the engine to ensure that oil flows freely through the oil inlet pipe.
3. Pre-lube the turbo with the recommended engine oil.
4. Rotate the compressor wheel by hand. If there is any indication of rubbing or scraping, identify the cause & correct before starting the engine.
5. Disable the ignition & crank the engine to ensure that oil flows free through the oil outlet hole, and then connect the oil drain pipe.
6. Connect the air ducting from the outlet of the air filter to the compressor inlet.
7. Start the engine & allow to idle for 3-4 minutes checking for oil, or exhaust leaks & also oil pressure build up.

Turbo Solutions Oil Priming Instructions

FOLLOW OIL PRIMING INSTRUCTIONS CAREFULLY!
PROTECT THE BEARINGS IN THIS TURBOCHARGER!

1. Disable engine by disconnecting fuel solenoid valve or shutting off fuel supply (diesels) or disconnecting ignition system (petrol engines).
2. When unit is fitted in position leave oil drain pipe disconnected, hold the compressor wheel in the front of the turbo, to prevent the shaft turning a single revolution and crank engine on starter motor in 10 second intervals, do not crank longer than this as starter may overheat (while the engine is cranking if the shaft is not held it may cause the turbocharger to seize up). Allow starter to cool for approx 15 seconds and crank engine over again. Continue to follow this procedure until oil flows from the drain pipe. This gives a visual indication that the oil supply is through to the turbocharger. If you cannot get the oil to prime through please telephone for advice.
3. Do not rely on the oil pressure as an indication that there is oil at the turbocharger. The oil feed pipe is a narrow section and will not cause a pressure drop sufficient to bring the oil light on even when it is full of air as most oil lights extinguish at only 5 PSI. When oil is primed through to turbocharger reconnect fuel or ignition system and start engine
4. Do not rev engine but allow idling for 3 minutes.
5. Check for any leaks and road test the vehicle.