How to replace your turbo

When switching turbo it is important that the installation is done correctly. Before installing an exchange turbo, it is important to find out why your old turbo has failed so that the new turbocharger doesn't break down for the same reason.

Exchange turbo

Always make sure that the correct turbo has been received before you begin to replace the turbo. Costs for assembly /dismantling of incorrect turbo are not covered by Nordic Motor Center. Compare the numbers on your old turbo with the new delivered unit.

Read the assembly instructions carefully before starting the assembly of your new turbo.

1. INTRODUCTION EXCHANGE TURBO

It is important that the installation of your new exchange turbo is done in a proper way. The exchange turbo is equivalent with a new turbocharger. Accuracy is essential when mounting the new turbo.

2. GENERAL RECOMMENDATIONS FOR ASSEMBLY OF EXCHANGE TURBOS

Always check before starting the assembly work that the correct exchange turbo has been received. This simple control can save you unecessary work.

NOTE!

Examine carefully why the old unit has failed.

Examples of reasons that may have caused a turbo breakdown:

Too little oil or low oil pressure in the engine.

Clogged oil pipelines to and from the turbo. We prefer to replace these pipes when changing turbo as it can be difficult to make them completely clean.

If the crankcase ventilation is clogged, crankcase ventilation can not be returned to the engine. This means that turbo can not get rid of the oil it gets from the engine, which means that the oil is forced out through gaskets and seals in turbo.

Foreign objects flying into the compressor wheel. Check and clean carefully the intake and intercoolers.

Leakage when air supply, clogged air filter.

3. CLEANING

We recommend a cleaning of intake and intercoolers, as well as oil pipelines to and from the turbo. We would prefer that you replace these pipes when changing turbo since it can be difficult to make them completely clean.

4. PROTECTION PLUGS

Our exchange turbos are provided with protective plugs during transport. Do not remove the protective plugs until just before installing the turbo. This reduces the risk that dirt/particles will end up in the turbo.

5. TIGHTENING OF BOLTS/SCREWS

Always tighten bolts/screws to the correct tightening torque according to specifications.

Some bolts/screws can only be used once. Lubricate the threads of the bolts with copper grease.

6. COOLING SYSTEM

Optimum cooling of the engine and turbo is very important. The cooling hose should be replaced if they have been damaged or become hard,
also replace the hose clamps if necessary.

Never fill the engine's cooling system with water, but with a mixture of frost protection fluid and water.

Use at least 30% antifreeze, this protects your cooling system from corrosion.

Ventilation of the cooling system: see the vehicle's manual. Check the cooling system for leakage.

7. AIR FILTER

Always install a new air filter.

A blocked air filter increases fuel consumption and can also damage the turbo. Wrong type of air filter or an incorrectly installed air filter may cause dirt or dust to enter the engine and turbo.

8. CRANKCASE VENTILATION SYSTEM

Generally, the ventilation works by two connections. A large sized hose from the crankcase/valve cover to an "oil trap" and a thinner hose from the "oil trap" to the air purifier/intake pipe. Pipes, connections and "oil trap" should be cleaned before assembly. A blockage can cause excessive pressure in the crankcase, resulting in oil leakage.
No part of the crankcase ventilation must be removed, it may cause a fire in the crankcase.

Regarding the turbos, a clogged crankcase ventilation can cause the turbo to not return the oil into the engine. This means that the turbocharger can not get rid of the oil it gets from the engine, which causes the oil to be pushed through gaskets and seals in the turbo with severe damages.

9. LUBRICATING SYSTEM

Oil and oil filters

Always replace the oil and oil filter. Replace the oil filter with the correct type. Some engines require an oil filter with an overpressure valve. Use an oil recommended according to the car manufacturer's recommendations.

10. FIRST START AND USAGE

Start-up

Before starting up the engine after installing an replacement turbo, check the following:

• There is enough oil in the engine
• All bolts and belts are tightened
• The cooling system is vented and filled with the right kind of coolant

Drive around the engine on the starter motor with the ignition cable removed from the spark plugs until the oil pressure lamp goes out. Only if the car manufacturer allows it. If the oil pressure lamp does not go out, fill the oil filter with oil and inject oil into the oil duct with an oil can to bleed the oil system. Reconnect the ignition cables on the spark plugs and start the engine. Immediately turn the engine up to 1500 rpm, check oil pressure and water temperature. Adjust the ignition and carburetor/injection according to the manufacturer's specifications. Make sure there is no leakage of coolant and oil. When you bleed the cooling system, fill with coolant to the recommended level.

Allow the engine to idle approximately 5 min after startup. Double check for leakage again.

Always allow the engine to idle at least one (1) minute after starting before it is loaded. The turbine housing must cool down before the engine is switched off, and this requires 3-5 minutes of idle after hard driving, otherwise the oil in the bearing house can boil and cause a new breakdown of the turbo. NOTE! Especially important for petrol engines.

Be careful with the change of oil, oil filter and air filter. Clean oil and clean air are the key to a long life for your new turbo.