During the replacement of TURBORAIL turbochargers and core assemblies, strict compliance with manufacturer and professional installation requirements is essential. In the vast majority of cases, turbocharger failures are not caused by the turbocharger itself, but by engine-related or auxiliary system faults.
The purpose of this information is to prevent repeat failures and to clearly define the conditions of warranty eligibility.
General Installation Requirements
Before installing a turbocharger, it is mandatory to inspect and, if necessary, clean or replace the following components:
-
Intake system (air filter, intake hoses, resonator, crankcase ventilation system)
-
Oil feed and oil return lines
-
Oil sump and oil cooler
-
EGR valve
-
Charge air system and intercooler
-
Catalytic converter and/or diesel particulate filter
The use of liquid sealants in the oil system is strictly prohibited.
Before installation, the turbocharger bearing housing must be pre-filled with engine oil, and the oil system must be primed prior to first start-up. After the first start, the engine must idle for at least five minutes. Engine revving during this period is strictly forbidden.
PSA 1.6 Engine Vehicles – Special Attention Required
Vehicles equipped with PSA-manufactured 1.560 cubic centimetre engines with 66 or 80 kilowatt output, commonly found in Peugeot, Citroën, Ford, Mini and certain Volvo models, are known to suffer from oil lubrication deficiencies.
For these engines, turbocharger replacement is considered correct only if the modified components are installed and all prescribed checks are carried out.
Typically required components include:
-
Modified turbo oil feed pipe and modified banjo bolt
-
Oil return pipe
-
Modified oil sump and oil dipstick
-
Oil pickup strainer
-
Engine oil, oil filter and air filter that strictly meet OEM specifications
The mesh filter inside the turbo oil feed banjo bolt must be removed.
Post-Installation Checks
After installation, the following checks are mandatory:
-
Oil pressure measurement at the turbo oil feed line
-
Crankcase pressure check
-
Test drive of at least thirty kilometres, including one full-load acceleration at the end
-
Diagnostic scan and fault memory check
For PSA 1.6 engines, an oil flow test is also required. At idle speed, a minimum of 0.3 litres of oil must return within sixty seconds through the turbo oil return line.
Warranty Conditions
If the above checks are not performed, the prescribed components are not replaced, or the installation is not carried out in accordance with manufacturer and professional guidelines, the risk of repeat turbocharger failure increases significantly and warranty claims cannot be accepted.
Warranty eligibility requires verifiable documentation of proper installation and all performed service procedures.
Downloadable Documentation
Detailed, vehicle-specific installation instructions are provided with the product documentation.
General installation guide
Supplementary appendix for the installation guide for 1.6PSI engines