Turbo Installation Checklist: Oil, Priming, Gaskets & First Start

Skipping these steps is the most common reason a new turbo fails within days, and it also affects your warranty.

Before fitting

Find and fix what killed the old turbo: oil supply, air filter and intake, exhaust and DPF, injectors and crankcase breather.
Check the part number on the new turbo matches the old one, including the actuator type.
Change the engine oil and oil filter to the grade your vehicle maker specifies.
Replace the turbo oil feed pipe, or clean it until no carbon remains. Clear any filter screen in the banjo bolt.
Check the oil drain pipe is clear, unkinked and runs downhill all the way to the sump.
Clean the intercooler and intake pipes if the old turbo leaked oil or broke apart. Fit a new air filter.
Inspect the exhaust manifold for cracks, broken studs and debris.

Use new gaskets and O-rings on every joint. Never reuse old ones.
Do not use silicone or liquid sealant on oil feed or drain joints.
Do not adjust the actuator rod. Electronic actuators may need a calibration or learn procedure with a scan tool.
Make sure no rag, bolt or debris is left in the intake or exhaust.

Prime the turbo: pour clean engine oil into the oil inlet and turn the shaft by hand.
Where possible, crank the engine for a few seconds with fuel disabled to build oil pressure before it fires.
Start and let it idle for a few minutes without revving.
Check every oil, coolant, intake and exhaust joint for leaks while it idles.

Drive gently for the first few hundred kilometres, avoiding full boost and high RPM.
Recheck the oil level and all fittings after the first drive.
After hard driving, idle for a minute or two before switching off.