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Below is a guide for fitting a BMW 525D Turbocharger, whilst we have tried to make it as comprehensive as possible you should consult your local dealer as your model may have specific fitting requirements that the aftermarket is as yet unaware of.
We always recommend Turbochargers are fitted by experienced mechanics with extensive Turbo knowledge.
1- Before fitting the fitter should be absolutely 100% sure that there is no underlying fault that has caused the previous Turbocharger to fail. The first time a Turbocharger fails it may be the Turbo at fault - if the replacement fails there is likely to another problem elsewhere.
2 - Remove absolutely all traces of the old contaminated oil, even the smallest particles of debris from the failed unit may immediately destroy the new Turbocharger - this is a very common failure reason. If the oil has began to solidify the entire engine may need to be completely degreased and steam cleaned.
3 - Replace oil supply lines and fittings, these lines often become plugged with solidifying oil which will restrict the oil feed and drainage. Check that the meeting surfaces are free from debris and apply the new gaskets. DO NOT USE A GASKET SEALANT!!
4 - Prime oil feed lines and bearing chamber to operational level - a turbocharger running for 1 second without oil does the equivalent damage to the turbo parts and bearings as an engine running without oil for 1 minute.
5 - Make sure all openings to the Turbo are open and not plugged or capped off - make sure that the air hose is fitted correctly, anything sucked into the impeller will destroy the fins. ENSURE THAT NO LOSE DEBRIS IS PRESENT IN THE AIR HOSES OR FILTER HOUSING!
6 - Shut off fuel or disable ignition and crank the engine for at least 15 seconds or until the oil pressure is raised.
7 - Allow the engine to fast idle (1,000 RPM) for 3 - 5 minutes to seat turbo seals and allow engine oil to reach desirable oil temperature - DO NOT REV THE ENGINE UNTIL THE OIL IS WARM!
8 - Always let the engine idle for 2 - 3 minutes before shut down, otherwise the turbo wll continue to spin without suitable lubrication and oil pressure.
9 - When changing the engine oil always use the manufactures recommended oil and replace the oil filter with an OEM part.
10 - Do not use any silicon gasket sealers or any type of thread tape
11 - If fitted with an intercooler, ensure that the unit is not contaminated with oil - this may enter the air intake causing damage to the impeller blades and internal bearings.
12 - Check engine breather system if present - if blocked the engine may use the turbocharger as a vent and force oil past the internal seals.