New Turbo Pre-Start Checklist

The first stages of running a turbo after a new installation is crucial to its performance and reliability. We highly recommend looking over the following checklist after installation but before starting the engine for the first time:

 

Oil Supply

Oil is crucial to the operation of a turbocharger as it can see rotational speeds of over 100,000rpm. Failure to provide a clean and consistent oil supply can cause an immediate failure. If replacing an old turbo it is recommended to replace the oil feed hose and any fittings or filters between the engine and turbo. Certain vehicles run banjo fittings with an internal filter screen which should be replaced when installing a new turbo and checked regularly.

 

Oil Return

Whilst a turbo needs oil to operate reliably it also cannot have too much inside the bearing cage and must be able to exit from the turbo freely. Special attention must be paid to the oil return/drain hose to ensure it is free of debris and oil can move easily. If replacing an old turbo it is recommended to replace this hose. If oil cannot exit the turbo it can pool inside and cause premature bearing failures leading to oil leaking into the compressor or turbine housing.

 

Intake and Exhaust Piping

Ensuring all piping before and after the turbocharger is leak free and secure will help prevent turbocharger over-speed conditions and producing excess heat. A small boost or exhaust leak will mean the turbo has to work harder to hit target boost and could cause failures to the turbo or surrounding components.

 

Wastegate Setup

For internally wastegated turbos please ensure adequate pre-load on the wastegate actuator rod. A general rule of thumb is to have the clevis hole 1/4 to 1/2 a hole off the centre of the pin so that the rod must be "stretched" to slip over, creating tension and ensuring the wastegate flap is firm against the housing.

For both internally or externally wastegated turbos ensure the correct spring is fitted inside and a hose is connected from the compressor cover to the top of the wastegate housing.

 

Turbocharger Priming

After all above points have been checked over and the car is ready to start it is recommended to prime the turbo with fresh oil first. This can be achieved multiple ways but an example procedure is as follows:

  • Install oil feed line to engine but leave the turbo end of the line disconnected
  • Place the oil feed line fitting that's not connected in a receptacle to catch any oil
  • With engine in a NO-START condition, crank engine WITHOUT firing until oil drains freely from the oil feed line
  • Connect oil feed line to turbo (with restrictor if provided), and install the oil drain hose, leaving the engine end of the turbo oil drain hose disconnected and directed into a suitable receptacle
  • With engine still in a NO-START condition, crank the engine WITHOUT firing until oil flows freely from the turbo oil drain
  • Connect oil drain, and dispose of any oil caught in the receptacle - your turbocharger is now primed with oil and ready for first start

 

First Start

  • Start the engine and allow to idle for approximately 3 minutes to purge any air in the system
  • Check all unions and fittings are tight and free from leakage
  • Check all hoses are routed away from heat sources and any potential chafing risks
  • Stop engine, re-check engine oil level and top up as necessary
  • Your turbocharger is now ready for use