A Turbocharger Installation Kit is the single most overlooked part of any turbo job, and skipping it is the fastest way to kill a brand-new unit within the first thousand miles. At PT Turbo, where we have been rebuilding and supplying turbochargers since 1978, we have seen more premature failures caused by reused gaskets, contaminated oil lines, and dry startups than by any actual defect in the turbo itself.
If you are replacing a turbocharger, the installation kit is not an upsell. It is insurance for the several hundred or several thousand dollars you just spent on the turbo. Here is exactly what goes into a proper kit, why each piece matters, and how to install it without voiding your warranty.
What Is Inside a Turbocharger Installation Kit
Kits vary by application, but a complete kit for a diesel or heavy-duty gas engine covers the full oil and mounting interface. The goal is simple: every surface that seals, feeds, or drains the turbo gets a fresh, correct component.
- Oil feed line and banjo bolts: Delivers pressurized oil to the center housing bearings. Old lines carry carbon buildup that restricts flow.
- Oil drain gasket: Seals the return line to the sump. A leak here starves the bearing or blows oil into the exhaust.
- Turbine and exhaust manifold gaskets: Multi-layer steel gaskets rated for exhaust gas temperatures above 1,300 degrees Fahrenheit.
- Intake and compressor housing gaskets or O-rings: Prevent boost leaks on the cold side.
- Mounting studs, nuts, and copper washers: Correct torque hardware, since reused fasteners stretch and fail.
- Coolant line gaskets (on water-cooled units): For turbos with a liquid-cooled center housing.
Some kits also include a small bottle of assembly oil for priming the bearings. If yours does not, buy a bottle separately. Never install a turbo dry.
Why You Need a Turbocharger Installation Kit
The turbine shaft in a modern turbo spins at 150,000 RPM or more, floating on a film of pressurized oil measured in microns. That bearing system has zero tolerance for debris, air pockets, or restricted flow. This is the core reason a fresh installation kit is non-negotiable.
Reused oil feed lines are the number one warranty killer we see. Carbon deposits inside an old line act like plaque in an artery, cutting oil volume to the bearing at exactly the moment the new turbo needs it most. Within minutes, the bearing overheats and the shaft seizes.
Old gaskets are the second problem. Once a multi-layer steel gasket has been compressed and heat-cycled, it will not seal a second time. A leaking turbine gasket bleeds exhaust energy and drives EGTs up, while a leaking oil drain pushes oil past the seals and out the exhaust, which looks exactly like a failed turbo but is actually an install error.
Most manufacturers, including Garrett and BorgWarner, will deny a warranty claim if the oil feed line and gaskets were not replaced. The kit protects both your turbo and your coverage.
Don’t Forget the Actuator
On variable-geometry and wastegated turbos, the actuator controls boost by adjusting vane position or opening the wastegate. It is a wear item that often fails around the same mileage as the turbo, and replacing the turbo without inspecting the actuator is a common mistake.
A sticking or leaking pneumatic actuator will throw boost codes, cause limp mode, and put strain on your new turbo. If yours is original and high-mileage, replace it during the same job while everything is apart. Learn how these systems work in this overview of the variable-geometry turbocharger.
We stock exact-fit pneumatic actuators for the most common diesel platforms:
- The Garrett Pneumatic Actuator 757979-5102 is available from PT Turbo for $240.94, a direct fit for many Garrett GT and GTB series units.
- For Mitsubishi TD03 applications, the Mitsubishi Pneumatic Actuator TD03 49S3118761 runs $104.33.
- The Mitsubishi Pneumatic Actuator 4918918935 is our most affordable option at $83.99.
- For heavier-duty Garrett variable-geometry setups, the Garrett Pneumatic Actuator 445963-0040 is $465.52.
If you are unsure which actuator matches your turbo part number, our team can cross-reference it. Just contact PT Turbo with your casting number.
OEM vs Aftermarket Installation Kits
Not all kits are equal. Cheap aftermarket kits often use single-layer gaskets, undersized banjo bolts, and generic hardware that does not match factory torque specs. Here is how the two compare on the components that actually matter.
| Component | Budget Aftermarket Kit | OEM-Grade Kit (PT Turbo) |
|---|---|---|
| Turbine gasket | Single-layer, warps under heat | Multi-layer steel, rated 1,300F+ |
| Oil feed line | Often not included | New line included or specified |
| Hardware | Generic, inconsistent grade | Correct grade and thread pitch |
| Copper washers | Reused or omitted | New crush washers included |
| Fitment | Universal, hit or miss | Application-specific |
The price difference between a bargain kit and a quality kit is usually under fifty dollars. Against the cost of a repeat failure, that math is not close.
How to Install a Turbo the Right Way
A clean install matters as much as the parts. Follow this sequence to protect your new unit and your warranty.
Step 1: Clean everything before the turbo goes on
Flush the oil feed and drain passages. Drain and inspect the oil pan if the old turbo failed catastrophically, because metal debris from a grenaded bearing will circulate and destroy the replacement. Change the oil and filter as part of the job.
Step 2: Prime the bearings
Fill the oil inlet with clean engine oil or assembly lube and spin the compressor wheel by hand to coat the bearing. This prevents a dry startup, which is the number one cause of first-hour failures.
Step 3: Install with new gaskets and correct torque
Never use RTV silicone on oil drain or turbine gaskets. Excess sealant breaks off and clogs the oil return. Torque all fasteners to spec in the proper sequence.
Step 4: Prime before you crank
Disable the fuel or crank the engine without starting until you build oil pressure. On diesels, this may mean cranking in short bursts. Once oil pressure is confirmed, start the engine and idle for several minutes before any load.
If your engine also runs high soot loads, inspect the EGR system and diesel particulate filter at the same time, since restrictions there raise backpressure and shorten turbo life.
New, Remanufactured, or Rebuild: Choosing Your Turbo
The installation kit is the same regardless of which turbo you install, but your choice of turbo affects total cost. Here is a straight comparison.
| Option | Typical Cost | Best For |
|---|---|---|
| New OEM turbo | Highest | Warranty-critical, newest platforms |
| Remanufactured turbo | 30 to 50 percent less than new | Fleet and owner-operator value |
| Rebuild your existing core | Lowest, keeps your casting | Hard-to-find or original units |
We stock both new and quality remanufactured turbochargers, built to OEM tolerances and balanced to spec. If you want to keep your original core, our turbocharger rebuild service restores it with new bearings, seals, and a balanced CHRA.
Whichever route you take, pair it with a fresh installation kit and the correct actuator. Browse the full catalog at our online store if you need to match parts to your application.
Frequently Asked Questions
Can I reuse my old turbo gaskets to save money?
No. Once a gasket has been heat-cycled and compressed, it will not seal correctly again. Reused turbine and oil drain gaskets are one of the most common causes of oil leaks and bo
Cross-Reference & Superseded Part Numbers
The turbochargers covered in this article match or supersede the following OEM and manufacturer part numbers. If you are searching by part number, these are the units stocked by PT Turbo for this application:
006393 • 006399 • 448734-5 • 5900-310-7418 • 773326-0001 • 775839-2 • 804878-5 • 812080-0001 • 836026-5006S • 844669-0005 • 844669-0007 • 857564-6001 • 880736-6001 • 881028-5002 • 888883-6001 • 888883-6002 • 891185-6001 • 893516-6001 • CHRA-T3-60-Trim-GAR • GTX2867R+Bolt-on+Turbo • GTX3071R+Bolt-on+Turbo • PTT-C30-020 • PTT-FIAT-004 • PTT-FIE-004 • PTT-FIE-006 • PTT-FIE-007 • PTT-FIE-008 • PTT-FIE-009 • PTT-FIE-017 • PTT-FIE-021 • PTT-FIE-022 • PTT-FIE-025 • PTT-FOC-010 • PTT-FOC-011 • PTT-FOC-012 • PTT-FOC-013 • PTT-FOC-020 • PTT-FOC-030 • PTT-FOC-033 • PTT-FOC-036 • PTT-FOC-050 • PTT-FOC-052 • PTT-FOC-056 • PTT-FOC-064 • PTT-FOC-071 • PTT-FOC-076 • PTT-FOC-086 • PTT-FOC-096 • PTT-FOC-B11 • PTT-FOC-B12 • PTT-FOC-B15 • PTT-FOC-B16 • PTT-FOC-B17 • PTT-FOC-B22 • PTT-FOC-B24 • PTT-HGC-069 • PTT-HSG-384 • PTT-HSG-426 • PTT-HSG-429 • PTT-HSG-430 • PTT-HSG-432 • PTT-HSG-434 • PTT-HSG-435 • PTT-HSG-436 • PTT-HSG-437 • PTT-HSG-444 • PTT-HSG-445 • PTT-HSG-446 • PTT-HSG-447 • PTT-HSG-448 • PTT-HSG-468 • PTT-HSG-470 • PTT-HSG-471 • PTT-HSG-473 • PTT-HSG-474 • PTT-HSG-476 • PTT-HSG-477 • PTT-HSG-490 • PTT-HSG-491 • PTT-HSG-518 • PTT-HSG-654 • PTT-HSG-655 • PTT-HSG-725 • PTT-HSG-790 • PTT-HSG-792 • PTT-LTS-001 • PTT-MS3-002 • PTT-MS3-003 • PTT-MS3-007 • PTT-MS3-022 • PTT-MS3-023 • PTT-MS3-038 • PTT-MUS-001 • PTT-MUS-005 • PTT-MUS-010 • PTT-MUS-011 • PTT-S60-002 • PTT-SR2-002 • PTT-STC-001 • PTT-TBO-001 • PTT-TBO-004 • PTT-TBO-022 • PTT-TBO-023 • PTT-TBO-024 • PTT-TBO-025 • PTT-TBO-036 • PTT-TBO-107 • PTT-TBO-340 • PTT-TBO-602 • PTT-TBO-604 • PTT-TBO-607 • PTT-TBO-612 • PTT-TBO-614 • PTT-TBO-617 • PTT-TBO-618 • PTT-TBO-752 • PTT-TBO-763 • PTT-TBO-764 • PTT-TBO-828 • PTT-TBO-846 • PTT-TBO-848 • PTT-TBO-915 • PTT-TBO-C16 • PTT-TBO-C44 • PTT-TBO-F83 • PTT-TBO-H93 • PTT-TBO-H94 • PTT-TBO-J19 • PTT-TBO-J22 • PTT-TBO-J23 • PTT-TBO-J24 • PTT-TBO-J26 • PTT-TBO-J27 • PTT-TBO-J29 • PTT-TBO-J30 • PTT-TBO-J31 • PTT-TBO-J32 • PTT-TBO-J42 • PTT-TBO-J43 • PTT-TBO-J44 • PTT-TBO-J45 • PTT-TBO-J46 • PTT-TBO-J47 • PTT-TBO-J55 • PTT-TBO-K54 • PTT-TBO-L30 • PTT-TBO-N23 • PTT-TBO-R94 • PTT-VEVO-158 • PTT-VEVO-159 • PTT-VEVO-200 • PTT-VVW-004 • PTT-VVW-047 • PTT-VVW-068 • PTT-VVW-088 • PTT-VVW-171 • PTT-VVW-173 • PTT-VVW-174 • PTT-WGT-019 • PTT-WGT-037 • PTT-WGT-093 • PTT-WGT-108 • TIL-WGT-035
Can’t find your number above? Contact PT Turbo — our team has been matching part numbers since 1978.
Need a Turbocharger?
PT Turbo has rebuilt and sold turbochargers since 1978. We stock remanufactured units for Cummins, Duramax, Power Stroke, Detroit Diesel, and more — backed by a 12-month unlimited mileage warranty and same-week shipping from San Bernardino, CA.
📞 (909) 824-1020 · 346 S I St. #3, San Bernardino, CA 92410 · [email protected]