How to Fit / Replace A Turbo Charger Turbocharger

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We are aim to make it easy for everyone to replace the turbo correctly.

Under years of manufacturing racing parts, Maxspeedingrods finds out more and more people are willing to install the turbo, this is a very interesting process but it is also difficult, we have heard of many failed experience, which caused bad results, so we made the mind to do this thing, hope every one who see this article can get a little benifit.



Find out the cause of Turbo failure before fitting

If your turbo start to have the condition as below, you need check the turbo system carefully.
1. Excessive Blue Smoke which may indicated:
Dirty air filter system
Excessive flow resistance in exhaust system/big bore exhaust
Oil drain pipe clogged
Crankcase breather clogged/piping restricted
Sludge in turbocharger center housing
Valve guide, piston rings, engine or cylinder liners worn/increased blow by
Dirty compressor or charge air cooler
Piston ring sealing defective
Excessive turbocharger bearing clearances
Engine oil level too high
Gasket sealer used on oil drain gasket

2. Excessive Black Smoke which may also indicated:
Dirty air filter system
Suction and pressure line distorted or leaking
Excessive flow resistance in exhaust system/ leakage upstream of turbine
Fuel system/injection feed system defective or incorrectly adjusted
Valve guide, piston rings, engine or cylinder liners worn/increased blow by
Dirty compressor or charge air cooler
Boost pressure control swing valve/poppet valve does not close
Foreign body damage to compressor or turbine wheel
Insufficient oil supply to turbocharger

3. Over Boost, Boost pressure too high, which might indicated:
Fuel system/injection feed system defective or incorrectly adjusted
Boost pressure control swing valve/poppet valve seized in closed position
Boost pressure sensing pipe split or incorrectly fitted
Wastegate actuator diaphragm split
Wastegate actuator calibration incorrect

4. Boost too low / no pressure, which might indicated:
Dirty air filter system
Induction and intercooler pipes collapsing
Excessive flow resistance in exhaust system/ leakage upstream of turbine
Fuel system/injection feed system defective or incorrectly adjusted
Valve guide, piston rings, engine or cylinder liners worn/increased blow by
Restricted intercooler or charge air cooler
Boost pressure control swing valve/poppet valve seized in the open position
Pipes to actuator and boost control valves incorrectly fitted
Turbocharger bearing damage
Foreign body damage on compressor or turbine
Turbine housing/flap damaged
Insufficient oil supply to turbocharger
Engine valve timing incorrect
Accelerator cable maladjusted
Insufficient fuel flow/pressure

5. Oil Leaking from Compressor Housing, it might caused by:
Dirty air filter system
Excessive flow resistance in exhaust system
Oil drain lines clogged, leaking or distorted
Crankcase ventilation clogged and restricted
Coke and sludge in turbocharger center housing
Valve guide, piston rings, engine or cylinder liners worn/increased blow by
Dirty compressor or charge air cooler
Piston ring sealing defective
Turbocharger bearing damage
Engine oil level high
Excessive oil pressure
High mileage engine

6. Oil Leaking from Turbine side:
Excessive flow resistance in exhaust system/big bore exhaust
Oil drain lines clogged, leaking or distorted
Crankcase ventilation clogged and restricted
Coke and sludge in turbocharger center housing
Valve guide, piston rings, engine or cylinder liners worn/increased blow by
Dirty compressor or charge air cooler
Piston ring sealing defective
Turbocharger bearing damage
Engine oil level high

7: Compressor/Turbine Wheel Impact Damage, they shows:
Turbocharger bearing damage
Defective air filter piping/system
Foreign body from engine damage entering turbine inlet
Excessive boost pressure

8: High Oil Consumption, the reason as below might cause it.
Dirty air filter system
Excessive flow resistance in exhaust system/big bore exhaust
Oil drain pipe clogged
Crankcase breather clogged/piping restricted
Sludge in turbocharger center housing
Valve guide, piston rings, engine or cylinder liners worn/increased blow by
Dirty compressor or charge air cooler
Piston ring sealing defective
Excessive turbocharger bearing clearances
Engine oil level too high
Gasket sealer used on oil drain gasket

9. Whistling/Cyclic Noise from Engine Compartment under load:
Inlet manifold gasket leaking or incorrectly fitted
Intercooler piping split/intercooler damaged
Exhaust manifold gasket leaking
Exhaust system corroded
Turbine housing mounting flange gasket leaking
Exhaust gas leakage between turbine outlet and exhaust pipe
EGR valve not seating correctly
EGR valve piping broken
Turbocharger bearings worn
Restricted air filter
Imbalanced turbocharger rotating assembly
Damage to compressor wheel inducer blades
Damage to turbine wheel assembly

As we talked above, there are many reason might cause the turbo failed, which can be short to 6 top reasons:
1. Oil starvation
2. Oil contamination
3. Impact damage
4. Blocked Engine breather
5. Over speeding of shaft and wheel
6. Hot shut down


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Find the right turbo suit for your application.

1. If you do have the turbo originally and just want to replace it with the same one. Check the turbo nameplate( a metal part) on the turbo compressor housing, there will have some numbers on it, these number is the most reliable number to find the right turbo to replace your old one.



2. If you want to change the turbo with larger horsepower or fast reaction, you can choose a universal turbo, they can be suit for almost 90% engines, but you need to know there might need lot of modification. As they have different sie and bolts flange and oil holes. when you choose a universal turbo, you need to know the engine capacity of your vehicle and the horspower you need. Please note that, if you need a larger horsepower turbo, then it's reaction speed will be a little slow, if you want it react fast, which means you need a small turbo, it's horsepower might be lower.
and pay attention to the cooling type, and wastegate, decide to choose a water cooled one or oil cooled one, an internal wastegate one or a external wastegate one.
You can also chose the universal turbo to match your manifold, if your manifold  is T3 manifold you can choose the T3  turbo as well, which will save you a lot of time and money.



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Checking Listing

Remove oil feed pipe and all associated banjo bolts and restrictors. Inspect for damage/blockage before refitting. Check there is a good clean oil feed to the turbo and that the flow and pressure is correct (recommend new oil feed pipe to be fitted) (especially if the pipe runs close to heat source) prime turbocharger before running engine.
Check all induction piping/airfilter box and airfilter are free from debris and that the turbine nut from the previous failure in not present.

Check there is a good clean oil feed to the turbo and that the flow and pressure is correct. We recommend new oil feed pipe to be fitted, especially if the pipe runs close to a heat source. Prime turbocharger before running engine.

Check engine breather and associated valves are working correctly and are free from debris.

Check oil drain pipe to sump is not blocked, restricted or damaged.

Do not use any type of sealer on any of the oil inlet and outlet connections to the turbocharger, also turbine inlet and outlet flanges.

Inspect EGR valve for correct operation.

Check ECU to manufacturers specifications and all associated boost control valves/pipes for correct operation.

Change oil and oil filter with correct type and grade of oil (refer to manufacturers specifications). It is very important not to overfill. (Modern engines are very slow fillers).

Check boost pressure does not exceed manufacturers limits.

Do not fit a replacement turbo to a worn engine.

It is advisable to let the engine idle for 45 seconds before switching engine off if it is driven hard to prevent bearing damage.
On certain Audi/VW applications the rocker cover should be replaced if the turbocharger compressor wheel has failed due to overspeed or debris damage. Particles can find it's way into the rocker cover breather. The design of this cover does not allow access to clean

If you have interest to get one turbo right now, please trust us, we are as professional as you expected.

We have many years of manufacturing turbochargers and chras experience, we produce lots of turbos, we can even provide custom service for you if you need, all of them are full tested and twice balanced, we own big engineer team and top technics, and we provide warranty for all of them.
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