step
by step

Installation
Guidelines

To assist our customer in installing our Niistu turbochargers effectively, we have compiled a comprehensive step-by-step guideline with visual aid below.

It is crucial that these installation instructions are followed, and failure to do so will result in premature turbocharger failure and warranty denial.

Turbocharger Installation Guideline

Step

1.

Check, understand and determine why the previous turbocharger failed. Ensure that all problems have been rectified before fitting a replacement unit.

turbocharger install-guide1

Step

2.

Carefully inspect and remove any dirt, dust, carbon deposits or other debris from the air cleaner duct, exhaust manifold and intercooler. Particles left in these areas can severely damage the turbocharger during engine startup. Replace the air cleaner if necessary.

turbocharger install-guide2

Step

3.

Always replace old gaskets with new ones. Thoroughly clean and remove any carbon deposits, sludge or blockages from the oil inlet and oil drain flanges.

turbocharger install-guide3

Step

4.

Perform a complete oil change prior to the installation of a new turbocharger.

turbocharger install-guide4

Step

5.

Perform air filter change prior to the installation of a new turbocharger.

turbocharger install-guide5

Step

6.

Install the turbocharger on the exhaust manifold flange and check for a tight seal for the correct fitting of turbine inlet gasket.

turbocharger install-guide6

Step

7.

Pre-lube the turbocharger by pouring clean engine oil into the oil feed hole of the turbo. Slowly rotate the rotor several times by hand to coat the turbocharger bearings with lubrication oil.

turbocharger install-guide7

Step

8.

Connect the oil supply line and air cleaner duct to the turbocharger. With the fuel shut off to prevent engine start, crank the engine for 10 – 15 seconds to build up oil pressure.

turbocharger install-guide8

Step

9.

Ensure the air cleaner duct, exhaust manifold and oil supply line are securely fastened. Use soapy water to help identify any gas leaks.

turbocharger install-guide9

Re-alignment of End Housing

Step

1.

Mount the turbine inlet flange onto the engine manifold to ensure easy setting of the turbocharger orientation.

Step

2.

Loosen the turbine housing bolts (a) or V-band nut (c) or G clamp nut (d) to allow it to rotate freely. Excessive loosening will result in damage of internal components of the turbocharger.

  • A
  • C
  • D

Step

3.

Loosen the compressor housing bolts (a) of V-band nut snap ring (e) to allow it to rotate freely. Excessive loosening will result in damage of internal components of the turbocharger.

  • A
  • E

Step

4.

Rotate the bearing housing so that the oil inlet & outlet ports mate with the turbo oil feed & drain line. Ensure the oil outlet port is at the bottom side.

Step

5.

Tighten all the fasteners of the turbine housing to secure orientation position.

Step

6.

Bend the locking tabs (b) (if available) upfront against a flat surface on each bolt head on the housing.

  • B

Step

7.

Rotate the compressor housing to the position where the air outlet ducting host can be installes properly. Secure and tighten air ducting host.

Step

8.

Tighten all the fasteners of the compressor housing to secure orientation position.

Type Of Fastener

Type Of Fastener

A Bolts

If bolts are used to fasten the turbine housing (or) compressor housing with bearing housing, use torque wrench with suitable spanner slot.

re-align-1-1
Correct Tool to be used :
BOX SPANNER WITH T HANDLE
B Locking Tabs

If locking tabs are used to prevent the loosening of bolts at turbine side, kindly straighten the thin plate using chisel and loose the bolts for re-orientation.

re-align-b1-2

To straighten the locking tabs, use chisel as shown in photo.

re-align-b2-2

To bend the locking tab again, use chisel as shown in photo.

Correct Tool to be used :
PIN PUNCH
C V-Band

If V-band is used to fasten the turbine housing (or) compressor housing with bearing housing, use box spanner with T handle.

re-align-c
Correct Tool to be used :
BOX SPANNER WITH T HANDLE
D G-Clamp

If G-clamp is used to fasten the turbine housing, use box spanner with T handle.

re-align-d
Correct Tool to be used :
BOX SPANNER WITH T HANDLE
E Snap Ring

If snap ring is used to fasten the compressor housing with bearing housing, use appropriate snap ring plier.

re-align-e
Correct Tool to be used :
SNAP RING PLIER