Do’s & Don’ts for Turbocharger

Do’s
• Ensure protective caps on all openings of turbo

• Ensure specially deigned trolleys are used for turbocharger storage on

assembly.

• Ensure pre lubrication of turbocharger.

• Ensure leak proof joints for oil & air. Check periodically.

• Ensure specified grade of lubricating oil.

• Ensure correct oil level in engine.

• Run engine at idle RPM for approx 1min. Before stopping & after
starting.

• Check air & oil filter condition regularly to the manufacturer’s

specification.

• Ensure that engine maintenance intervals are adhered to.

• Ensure engine & equipment are operated in such a way that it is not
harmful to the life of turbocharger.
Don’ts
• Do not store turbochargers in heaps.

• Do not store turbochargers in moist or wet place.

• Do not expose turbocharger to dust & dirt.

• Do not hold turbocharger by actuator rod.

• Do not add any additives in lubricating oil & fuel unless until specified.

• Do not raise the engine RPM immediately after starting.

• Do not disturb actuator settings.

• Do not run the vehicle / engine at idle for long periods (more than 20 – 30
mins).

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Good Operating Practices

Operators and owners can help themselves to get maximum service life from their
turbochargers if a few good practices are followed:-
1. Start Up
When starting the engine use minimum throttle and run in idle mode for approximately one
minute. Full working oil pressure builds up within seconds but it is useful to allow the
turbocharger moving parts to warm up under good lubricating conditions. Revving the engine
within the first few seconds of start up causes the turbocharger to rotate at high speeds with
marginal lubrication which can lead to early failure of the turbocharger.
2. After Servicing
After servicing the engine or turbocharger ensure that the turbocharger is pre-lubed by
adding clean engine oil into the turbocharger oil inlet until full. After pre-lubing crank the
engine without firing (engine/fuel pump stop out) to allow oil to circulate through the full
system under pressure. On starting the engine, run at idle for a few minutes to ensure the oil
and bearing systems are operating satisfactorily.
3. Low Air Temperature & Inactive Operation
If the engine has been inactive for some time or the air temperature is very low, crank the
engine first and then run at idle. This allows the oil to circulate throughout the full system
before high loads and speeds are applied to engine and turbocharger.
4. Shut Down
Before shutting your engine down, let the turbocharger cool down. When an engine runs at
maximum power/high torque, the turbocharger is operating at very high temperatures and
speeds. Hot shut down can cause reduced service life which is avoidable by a minute or two
of idling. Most mobile equipment applications include an adequate cooling period during
parking or mooring procedures
5. Engine Idle
Avoid running your engine for long periods in idle mode (greater than 20-30 minutes). Under
idling conditions low pressures are generated in the turbocharger which can cause oil mist to
leak past seals into the two end housings. Although no real harm is done to the turbocharger,
as load is applied temperatures increase and the oil will start to burn off and cause blue
smoke emission problems.

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Installation Instructions

Always understand why the original turbocharger needs replacing, determine the cause
of any failure and rectify it before fitting a replacement unit. If in doubt contact
HTIPL.

Important Notes:

1. Failure to follow these instructions can lead to turbocharger damage and void
warranty.
2. Changing the calibration of turbocharger damages the turbo / engine and voids
warranty.
3. Correct gasket must be used – they should not overlap holes.
4. Refer to engine / vehicle manufacturer literature for correct oil type and
quantity. Also for correct torque and installation details.
1. Gasket covering part of oil hole reduces oil supply to turbo or if gasket
material breaks away, may totally stop oil flow.
2. Liquid gasket or sealant is not recommended, particularly for oil inlet /
outlet.
5. Prevent dirt / debris from entering any part of the turbo during installation.
6. Before fitting the turbocharger, check that the part number is correct one for
the engine – fitting the incorrect turbo to an engine may damage the turbo /
engine and will void the warranty.

Installing the Turbocharger:

1. All air hoses connected to the turbo must be totally clean and undamaged.
2. Air filter and housing must be totally clean and free from debris.

Check air filter

3. Clean engine breather system and check function.
4. Remove old gasket material from the exhaust manifold and pipes. Faces must
be undamaged.
Remains of old gasket

Remove old gasket material

5. Remove plastic or foam blanking plugs from the turbo before fitting.

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6. Fill the oil inlet hole of the turbocharger with new engine oil and spin the
compressor wheel by hand a few times – it should spin freely. It is normal to
feel some play on wheels.

Pre lubrication of turbocharger

7. Fit the turbochargers on manifold or engine block (as applicable) using the
correct new gasket or joint ring, and then reconnect the exhaust pipe. Tighten
all nuts / bolts. Check condition of studs & flange – They should be
undamaged.

Check mounting stud & flange for damages & cracks

8. Oil feed and drain lines must be totally clean and undamaged – oil flow must
be unrestricted. Check that any flexible hose liners have not collapsed
internally.

Damaged oil return line

can cause restriction to oil
flow & oil leakage from
turbocharger.

9. Check that oil feed line not too close to source of heat. Oil level OK, but drain
line damaged causes oil leakage from turbo.
10. Fit oil drain line. Refill the oil inlet hole with new clean engine oil reconnect
the oil feed line.
11. Fit air hoses and tighten.

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12. Use new air, oil and fuel filters, refill engine with new clean engine oil.

Change air, oil & fuel filter

13. If possible prevent the engine from firing and crank the engine for 10 -15
seconds to prime oil feed. Start the engine and idle for 3 to 4 minutes before
increasing speed. Check for oil and gas / air leaks.

Check engine for gas, air & oil leakage

14. Stop engine and recheck engine oil level – Oil level should not be above the
point where oil returns from the turbo to the engine.

Too high oil level Oil level high, but just Oil level OK.
in engine restricts below oil drain. No problem.
oil flow& causes Crankshaft rotation
oil leakage from causes oil to sweep over
turbo. oil drain – Oil leakage

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15. Check crankcase pressure. High pressure may be caused by piston bypass or
blocked breather system.

PCV Valve

Piston / Piston ring PCV Valve not

worn out – Causing working or breather
excessive blow by & choked – Causing
crankcase pressure high crankcase
pressure.

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Turbocharger Inspection Guide Lines
1) Check the compressor / Turbine wheel for damages

No damage - OK

No damage - OK

2) Check the compressor / turbine wheel for rubbing with

housing.

No Rubbing - OK No Rubbing - OK

3) Check the rotor for free rotation.

Free Rotation -
OK

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