TURBO REBUILD GT15-25 1st Generation Turbocharger Repair Rebuild Service Repair Kit Installation Guide
- June 1, 2024
- TURBO REBUILD
Table of Contents
TURBO REBUILD .CO.UK
YOUR TURBOCHARGER
YOUR ORDER • KEY FACTS
GT15-25 1st Generation Turbocharger Repair Rebuild Service Repair Kit
YOUR ORDER
Thank you for choosing Turbo Rebuild for your Turbocharger needs.
This booklet aims to inform you of the installation process to safely get you
back on the road, alongside our Warranty and Returns policy.
KEY FACTS
- Built and balanced in the UK
- Parts meet or exceed OE specification
- 12 months warranty on CHRAs
- 12 months warranty on Turbochargers
BUILT AND BALANCED IN THE UK
PARTS MEET OR EXCEED OE SPECIFICATION
WE SELL PARTS TOO!
TURBO REBUILD LIMITED
01253 799987 | [email protected]
INSTALLING A NEW TURBOCHARGER
First thing’s first, why did the original turbo unit fail? Did you know that
over 90% of turbocharger failures are caused by an outside influence?
This can be oil contamination, oil starvation, incorrect turbo boost pressure,
foreign object damage, as well as blocked engine breathers, CATs and Diesel
Particle Filters. Before fitting a new turbo unit, you MUST find the cause of
the original failure and correct it before fitting the new unit.
INSTALLATION INSTRUCTIONS
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Before removing the turbo, we advise you let the engine idle to operating temperature before switching off and draining the engine oil from the sump (take good care as oil will be extremely hot). As the oil is more fluid when warm, you have a greater chance of removing as much as possible. NOTE: If the turbocharger has completely failed, and if oil is found in boost pipe work, this point must NOT be undertaken.
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Next, refit the sump plug and fill sump with a high quality engine flush and, following the instructions on the container, flush the engine before again removing the sump plug and draining completely.
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Now remove the oil filter and dispose of it. Remove the old turbocharger as well as ALL oil and turbo boost pipe work.
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Check all turbo boost pipe work for splits, holes or damage and ensure oil and dirt is removed. If damaged, replace.
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Remove turbo intercooler (if fitted) and flush with an oil de-greaser before leaving to drain completely.
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Remove air filter and dispose of before checking air box for damage.
Clean and fit new filter element. -
Check EGR, where fitted, to ensure correct operation is seen. Clean/replace as required.
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Upon fitting new turbocharger, ensure all turbo gaskets are replaced and that all bolts and nuts are tightened to manufacturer settings.
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Refit turbo intercooler and all turbocharger boost hoses, ensuring they are seated correctly and fasteners are in a good condition.
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Once turbo and all boost pipe work are refitted and checked, fit a NEW turbo oil feed pipe. The reason for this is turbo oil feed pipes are often revised in design to overcome past issues. Before connecting the turbo oil feed pipe to the turbo itself, squirt some engine oil into the turbo oil inlet to ensure the turbo doesn’t run dry on start-up.
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Once oil feed pipe is connected, a visual check is required on everything you have done to ensure all parts are connected correctly and securely.
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Fit a NEW oil filter and a refill sump with correct grade of oil. If possible, fill oil filter with oil prior to fitting to ensure a delay in oil supply to the turbo isn’t found as the filter and lines fill on first start.
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If possible, crank engine without starting for 5 second intervals, allowing a break in between for the starter to cool. Otherwise, start the vehicle WITHOUT revving the engine.
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Allow engine to idle until up to operating temperature and then switch off. Check oil level is correct and check for any leaks.
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On first drive, drive vehicle gently, allowing turbo to spool up gradually without accelerating fully.
This completes the initial installation. We advise an oil and oil filter
change after 100 miles and then further servicing as per the manufacturer
guidelines.
If you are unsure in any way about fitting your new turbocharger, please
contact us.
WARRANTY
WARRANTY FORM
Our units are built with brand new components and are highly balanced in up to
3 stages, with the final balance run checking for leaks and noise issues. We
will never dispatch any units that have not passed these detailed tests. The
units are quality checked by two individuals before leaving our workshop to
ensure they are of our best work.
However, if you believe your Turbocharger or CHRA has an issue, this must be
returned to us following our strict Warranty process. The unit must not be
tampered with after removal, must be boxed safely to ensure no damage is
acquired in transit, and must accompany a warranty form.
When the unit arrives back, the unit will be visually inspected, before a
complete strip down to component form. Each component will then be inspected
for damage, size and clearance to discover the cause of the issue. A warranty
report will then be written up by one of our specialist technicians, which
will be accompanied by photos.
If found to be faulty and the warranty claim is accepted, then Turbo Rebuild
will repair and return the unit free of charge. This warranty cover does not
include any ancillary parts to the Turbocharger or any other costs incurred by
the customer.
Upon concluding that the findings are not a result of a faulty product and the
warranty claim is not accepted, the owner will be given the decision as to the
outcome of the parts that remain, but will be liable for any costs incurred.
TO DOWNLOAD A COPY OF THE WARRANTY FORM AND TO VIEW THE FULL TERMS AND
CONDITIONS, PLEASE GO TO:
WWW.TURBOREBUILD.CO.UK/WARRANTY
RETURNS
HOW TO RETURN A PRODUCT
If you wish to return an unused item for any reason, you must do so within 14
days of the date of receipt of the item. The item must be returned in an
unused and resaleable condition, and buyer must ensure the item is packaged
well to avoid damage in transit.
Items must be returned alongside the original invoice, or copy of, otherwise
we will be unable to identify who has returned the item.
Refunds will be processed within 3 working days of receipt of the item and
payment will be refunded back to the original payment.
Turbo Rebuild Limited cannot be held responsible for any incorrect items
ordered without supplying us with the turbocharger part number prior to
purchase, as this is the only way we can 100% guarantee fitment of the part.
If you have any further queries, please do not hesitate to contact us using
the information provided below.
CONTACT US:
Turbo Rebuild
Unit 1, Pointer Stables
Lancaster Road
Preesall
FY6 0HN
Phone: (01253) 799987 Email:
[email protected]
FAQ
CHECK HERE FOR OUR FREQUENTLY ASKED QUESTIONS
QUESTIONS/QUERIES:
Q: My turbo has arrived back and there is play in the shaft.
A: A turbo's design requires the shaft assembly to float on a layer of oil. This means that there must be sufficient clearance around all moving components to allow the cushion of oil to flow around these components. All parts have been measured to ensure the clearances are within the specifications set by OE manufacturers.
Q: My turbo has arrived back and there is oil leaking.
A: Whilst balancing, the turbo is fed with oil to ensure correct lubrication. Once assembled, there may be some oil still present that can leak out. We try, where possible, to fit bungs etc but this doesn’t always prevent some leakage in transit. Don’t worry, this isn’t the seals leaking (any issues with seals leaking would be found at the balancing stage and corrected).
Q: There are parts missing off the returned turbo.
A: In order to ensure ancillaries are returned undamaged and also to allow you to ensure these are fitted and orientated correctly, you will find all ancillaries are in a separate bag inside the box.
Q: What are all the blobs of paint for?
A: After assembly, the unit goes through various calibration stages. This ensures the unit performs like an original. To make sure the settings are not affected by vibration, we “lock off” the parts with an anti tamper paint. Please do not adjust any settings.
Q: Why is there a crack in the exhaust turbine housing?
A: It is very common for turbine housings to crack, especially around the wastegate penny. This is due to the large heat differentials seen in the housing, with the large amount of heat cycles together with the friction caused by the hot exhaust gases passing through a small wastegate hole. We inspect all cracks to ensure they are not structural and that the wastegate penny closes correctly to make sure the unit performs as required. We have, after much research, found that a new housing will almost certainly crack after a short period of use, and that welding up of cracks moves stresses to another point, resulting in further cracks. We ask you to be aware of boost issues in the future and to inform us of these so we can check the problem has not worsened.
Q: Why don't I have all the gaskets I need?
A: Many of the gaskets are not available unless buying a NEW turbocharger. We are continuously looking to source all gaskets, but this isn’t always possible. All units are returned with an oil drain gasket. Exhaust gaskets etc are usually a stainless steel ribbed type of gasket and can be reused, otherwise they need to be purchased from a main dealer or exhaust supplier.
Q: What is the oil syringe for that arrived with my new unit?
A: This is an oil priming syringe, which needs to be injected into the oil inlet of the turbo before the oil feed pipe is connected, to ensure that the turbo has oil on the first fire up. It is still advised that the installation instructions are adhered to so that the turbo is correctly primed.
Q: Does my unit need 'running in'?
A: The unit does not need 'running in', but it is advisable to avoid aggressive driving for 100 miles.
ABOUT US
WHAT ELSE DO WE DO?
SERVICING AND PARTS
Services
- Turbo Rebuilding and Reconditioning
- Turbo Upgrades
- Balancing and Calibration Services
- Actuator Repair
- Rotor Balancing
Parts
- Genuine OE Turbochargers
- CHRAs
- Bearing Housings
- Nozzle Rings
- Compressor Wheels
- Turbine Shaft & Wheels
- Heat Shields
- Seal Plates
- Gasket Sets
- Repair Kits
- Actuators
And much more!
WEBSITE:
TURBOREBUILD.CO.UK
FACEBOOK:
TURBO REBUILD
INSTAGRAM:
@TURBOREBUILD
CONTACT US:
Turbo Rebuild
Unit 1, Pointer Stables
Lancaster Road
Preesall
FY6 0HN
Phone: (01253) 799987 Email: [email protected]
REMOVE
RED
TRANSIT
BUNGS
BEFORE
FITTING
Version 2.0 | September 2023