FAQ – Frequently asked questions

Before you buy: fitment & compatibility

How do I know which Falcon turbo fits my car?

Each product page lists the OEM part numbers and compatible turbo numbers the unit replaces. If your existing turbo carries one of those numbers, the Falcon unit is a direct fit.

If you are not sure, the fastest way is to send a photo of the part number sticker on your current turbo, along with your car’s make, model, engine code and year, to info@falconturbos.com or via WhatsApp on +44 7932 301515. The team will confirm the correct match before you order.

What information do you need from me to confirm a fit?

The minimum we need is:

• Make, model and year of the vehicle
• Engine code (e.g. N57D30, BKD, OM642)
• The part number from your current turbocharger (stamped on the unit or on a sticker)
• Whether the car has been modified (remap, larger injectors, downpipe, etc.)

The more you tell us, the faster we can confirm.

Do you make turbos for petrol engines, or only diesel?

Falcon Turbos primarily develops upgrade turbochargers for diesel engines, where the demand and gains are highest. Some petrol applications are covered. The fastest way to check is to search your engine code on the shop page or to contact the team directly.

What’s the difference between BCW, Stage 1, Stage 2 and Stage 3?

• BCW (Billet Compressor Wheel) units are direct replacements for factory turbos. They can run on a stock map or a mild remap and are the safest upgrade if you want more power without changing supporting hardware.
• Stage 1 typically refers to a mild upgrade designed to work with a remap but without major engine modifications.
• Stage 2 units require a remap before driving and benefit from a larger intercooler and uprated downpipe.
• Stage 3 units are aimed at higher-output builds, require full supporting modifications, and are not suitable for road use without significant engine preparation.

Each product page lists exactly which stage the turbo is and what supporting mods are required.

Ordering, shipping & customs

Do you ship internationally?

Yes. Falcon Turbos has shipped worldwide for over 10 years. The website automatically deducts UK VAT for all delivery addresses outside the UK.

How long does delivery take?

• UK: usually next day, please allow two to three working days.
• EU and rest of world: depends on the destination and courier. Tracking is provided by email once the order is dispatched.

Will I have to pay import duties or customs charges?

Possibly, yes. If your delivery address is outside the UK, you may be liable for import duties or customs clearance fees in your country once the shipment arrives. These charges are set by your local customs authority and are not collected at checkout. Please contact your local customs office in advance if you want to know the likely cost.

Will I get a tracking number?

Yes. Once your order is being prepared for shipping, the courier will email tracking information to the email address you provided at checkout. If you have not received tracking within 2 working days, please email info@falconturbos.com.

My order arrived damaged. What do I do?

If you notice damage to the parcel or contents on delivery, contact info@falconturbos.com as soon as possible. Damage or shortage claims need to be reported within 5 days of delivery, otherwise the courier may refuse to process the claim. Please keep all the original packaging and take photos of the damage before opening anything further.

Payment options

What payment methods do you accept?

PayPal, MasterCard, Visa, Stripe and Klarna (Pay in 3).

Can I pay in instalments?

Yes, through Klarna’s Pay in 3 product. Your purchase is split into three equal payments: the first is taken when the order is confirmed, the second 30 days later, and the third 60 days later. There is no impact on your credit score for using Pay in 3.

Where do I manage my Klarna payments?

Through the Klarna app or by logging in at app.klarna.com/login. Klarna’s own customer service handles all questions about scheduling, missed payments and refunds for the Pay in 3 product.

What if I return an order paid with Klarna?

Follow the standard Falcon Turbos return process. Once Falcon Turbos has processed the return, Klarna will issue an adjusted statement and refund any amount you have already paid. Log into your Klarna account and select “Report a return” to pause your statement during the process.

What is included & what else you need

What is necessary in order to fit a Falcon turbo?

To fit a Falcon upgrade turbo you need:

• Brand new gaskets
• A full service kit with high-quality oil and filter
• In most cases, the EGR and DPF need to be professionally cleaned or replaced with new OEM units

Stage 2 and Stage 3 turbos additionally require:

• A larger intercooler
• A stainless steel exhaust (not suitable for road use)
• Larger MAP sensors if the boost exceeds the original sensor threshold

Are gaskets and fitting hardware included with the turbo?

A gasket kit is included with every turbo we ship. You will still need to source a full service kit (high-quality oil and filter) and, where required, new oil feed and return lines separately as part of the fitting job.

Do I need a new oil feed and oil return line?

Strongly recommended. Old oil lines are a common cause of oil starvation or contamination, both of which void the warranty. Replace them as part of the fitting job.

Do I need a remap with my new turbo?

It depends on the unit:

• BCW range: can run on the factory map or a mild remap.
• Stage 2 and Stage 3: must be remapped before the car is driven. Driving an unmapped Stage 2 or 3 turbo raises exhaust gas temperatures fast and will damage the turbo or the engine.

What supporting mods do I need for a Stage 2 or Stage 3 turbo?

At minimum: larger intercooler, stainless steel performance exhaust, and where applicable a larger MAP sensor. Stage 3 setups generally also require uprated injectors, fuel pump and clutch depending on the engine.

The team will confirm the exact supporting mod list for your specific application before you order. This is not something to guess at.

Installation & fitting

Can I fit a turbocharger myself?

Fitting a turbocharger is a meticulous procedure that requires thorough knowledge of the specific engine, turbocharger principles, and correct priming procedures. Warranty claims are only accepted if the turbocharger is fitted by a professional garage that can provide a valid receipt.

In practice: even if you have the skill to do it yourself, doing so will void the warranty. Given the cost of a hybrid turbo and the cost of an engine repair if something is fitted incorrectly, having a professional do it is the safer call.

Why does the warranty require a professional garage?

Because the vast majority of turbo failures in the first 1,000 miles come from installation errors: oil starvation, contamination from leftover debris in old oil lines, missed priming, or silicone sealant migrating into the oil feed. These failures look like a faulty turbo but are caused by the fitting process, which is why the warranty is conditional on a professional install with a receipt.

Can I use silicone sealant when fitting the turbo?

No. Use of silicone is strictly forbidden when fitting a Falcon turbo. This applies to the oil feed, oil return, air inlet, air outlet, exhaust inlet and exhaust outlet. Any sign of silicone around the turbo will void the warranty. Use proper gaskets only.

How do I prime the turbo before first start?

Before starting the engine, fill the new oil feed line and the turbo’s oil supply port with fresh oil and crank the engine without firing it for a few seconds to build oil pressure. This prevents the bearings running dry on first start, which is the single most common cause of premature turbo failure.

Your fitter should know this, but it is worth confirming.

What checks should I do before the first drive?

• Confirm no oil or coolant leaks at the turbo
• Check intercooler pipework is tight, no air leaks
• Confirm the actuator and any electronic actuator wiring are properly connected
• Verify there is no debris in the intake side
• On a hybrid turbo, confirm the remap has been loaded before you drive

ECU tuning & mapping

Do I need to tune my car to run an upgraded turbocharger? Can I drive my car without an ECU tune?

Our BCW (Billet Compressor Wheel) range is designed to directly replace factory units, so it can be run on either a factory map or a mild remap intended for vehicles with factory hardware.

Stage 2 or larger units should always be mapped before driving.

Even if you fit your turbocharger without all the supporting mods (performance intercoolers, larger downpipes etc.), it is vital to make sure your AFR (Air Fuel Ratio) and EGT (Exhaust Gas Temperature) are within the acceptable range for your engine. A turbo will not save a poorly tuned car from itself.

How do I get the ECU tuned for a Falcon turbo?

To assist your tuner, Falcon Turbos can supply the size of the turbo and the parameters where it is most efficient. After an initial test drive, the car needs to be data-logged. The tuner then assesses the engine’s capability based on the setup, turbo size, injector wear and so on.

The tuner should start at safe pressures and incrementally increase boost by 0.1 to 0.2 bar at a time until diminishing returns show that the turbo has reached its efficiency limit. They then wind the boost down slightly to keep things safe in long-term use.

If your tuner has not worked with the specific Falcon unit before, contact Falcon Turbos and the team will share the relevant parameters.

Will my car pass an MOT or emissions test after a Falcon upgrade?

Performance turbochargers that require modifications to engine or emissions control systems, including but not limited to DPF (Diesel Particulate Filter) removal, EGR (Exhaust Gas Recirculation) modification or deletion, or other emissions-related alterations, are intended solely for use in closed-course competition, off-road, or track environments where permitted by applicable laws and regulations. Such products are not designed, approved, or intended for use on public roads or highways. It is the responsibility of the vehicle owner and installer to ensure compliance with all applicable local, national, and international laws and regulations.

Can I keep my existing remap, or do I need a new one?

If your existing remap was written for the factory turbo, it will not be optimised for the Falcon unit and may push too much boost or too little fuel. You should book a fresh map session with your tuner after fitting the upgrade. Most tuners offer a discounted re-map if you used them recently.

Performance, reliability & fuel economy

Does an upgraded turbocharger compromise engine reliability?

No. The BCW range is a good example: it was developed using years of experience remanufacturing and refurbishing original turbochargers. Falcon Turbos has extensive data on how factory units failed and how they could be improved. From that data, the BCW range was developed to be a direct replacement for worn or failed factory units, with better performance and better longevity by addressing the specific weak points of the original unit.

That said, when fitting a larger turbocharger, it is important to be aware of the age and condition of your engine components. A larger turbo does not automatically mean engine failure, but the engine is being asked to handle more power than it was designed for at the factory. The Falcon units are designed for this load, the BCWs are stress-tested above the pressures they will ever experience on a vehicle, and the unique high-flow turbines are designed to reduce drive pressure (also known as Exhaust Manifold Pressure or EMP), which helps the engine breathe easier and reduces EGT, both crucial for the long-term health of a diesel engine.

Will an upgraded turbo affect my fuel economy?

With the BCW units you will likely notice an improvement in fuel economy, mostly from running a fresh turbocharger rather than a worn one. There are also dedicated “ECO” tunes that can push fuel economy further.

With a larger turbocharger it is more complicated. To keep your AFR and EGTs within acceptable limits, more fuel needs to be injected for a complete burn, so fuel economy depends heavily on how the car is tuned. On the other hand, with more power available you may not need to drive as hard, which improves economy. Too many variables to give one number – it depends on the build and the driver.

How much power gain should I expect?

This depends entirely on the specific turbo, the engine, the supporting mods and the tune. Each product page lists the indicative output. As a rough rule:

• BCW direct replacement: modest gain on top of stock, plus a return to peak factory performance from a worn unit
• Stage 1 / mild hybrid: 10-25% over stock
• Stage 2: 25-50% over stock with full supporting mods
• Stage 3: 50%+ over stock, build-dependent

Real numbers vary, the team can give you a realistic estimate for your specific car before you order.

Will the car feel different to drive?

Yes. Most owners report stronger mid-range pull, faster spool from a worn factory turbo to a Falcon unit, and better response under load. The exact feel depends on the tune. A good tuner can dial in the character you want – a hard-hitting peaky setup or a smooth wide-band setup – within the limits of the turbo.

Warranty

How long is the warranty?

12 months, starting from the date of sale.

What does the warranty cover?

If the product proves defective during the warranty period due to faulty material or workmanship, Falcon Turbos will, at its option, either supply a replacement or repair the defective product free of charge.

What does the warranty NOT cover?

The warranty does not cover damage caused by:

• Foreign object impact from the exhaust or air intake
• Oil starvation or oil contamination
• Over-boost
• Excessive exhaust gas temperature or pressure
• Use of silicone sealant on the turbo (oil feed, return, air inlet, outlet, exhaust)
• Driving a Stage 2 or Stage 3 hybrid turbo without a remap
• Driving a hybrid turbo without the recommended supporting mods
• Any form of racing
• Lack of proper servicing in accordance with the vehicle manufacturer’s recommendations

The warranty also does not apply if the turbo was not fitted by a professional garage with a valid receipt.

Does the warranty transfer if I sell the car?

No. The warranty is between Falcon Turbos and the first end-user. If you sell the car or engine, the unexpired warranty does not automatically pass to the new owner.

What if I want to claim under warranty?

Contact info@falconturbos.com with your order number, fitting receipt from the garage, and a description of the fault. The team will guide you through returning the unit for assessment. Note: no replacement is dispatched until the returned unit has been received and assessed.

If an independent specialist report or supplier report concludes that the turbocharger was not faulty (or the fault was caused by installation or an engine fault), the cost of testing and any other expenses will be charged to the buyer.

Returns, exchanges & sending your turbo back

What is your return policy?

If the product is unused and you have changed your mind, you must notify Falcon Turbos within 14 days of receiving the goods, in accordance with the Consumer Contracts Regulations 2013. You then have a further 14 days to return the item.

You are responsible for return shipping costs and for ensuring the goods are adequately insured in transit. Any damage during return delivery may result in repair costs charged to you.

Items returned outside the 28-day window may be accepted at Falcon Turbos’ discretion and will be subject to a restocking fee of up to 40%.

How does the exchange / core deposit work?

If you order a turbo on an exchange basis, your old turbo (the “core”) forms part of the price. If you don’t send the old unit with the order, a surcharge (“core deposit”) is added at checkout. That deposit is refunded once Falcon Turbos receives your old unit and confirms it meets the exchange criteria.

The old unit must be returned within 60 days of the sale. If it isn’t returned in time, the deposit is kept.

What condition does my old turbo need to be in for the exchange?

The exchange unit must:

• Not be externally damaged, disassembled or missing any integral parts
• Have part numbers matching the unit you bought

Incorrect or damaged exchange turbos will be rejected and the deposit will not be refunded.

How do I send my old turbo back?

Full step-by-step guide here: falconturbos.com/send-your-turbo/

Short version:

1. Contact Falcon Turbos first – this makes the whole process faster
2. Pack the turbo in a sturdy box with thick layers of cushioning material on all sides
3. Wrap the actuator (especially electronic actuators) in extra bubble wrap
4. Include the filled-in Exchange Form inside the box
5. If sending from outside the UK, also include a Customs Declaration on the outside of the box
6. Tape the box securely – top to bottom, around the sides, 2 to 3 full wraps
7. Ship via a tracked international courier (FedEx, DHL, UPS, DPD recommended for non-UK)

Shipping address:

Falcon Turbo Developments Ltd Unit 23, Nutwood Trading Estate Limestone Cottage Lane Sheffield S6 1NJ United Kingdom

Can I get a refund of my core deposit?

Yes, once the old unit has been received and confirmed as meeting the exchange criteria. Refunds can only be issued via the original payment method.

Troubleshooting after fitting

I am having underboost fault codes after fitting an upgrade turbo. What now?

Underboost codes can come from several sources after a turbo upgrade:

• Actuator calibration: the new turbo’s actuator may need to be calibrated for your specific car
• Vacuum or boost leak: a small leak anywhere in the intake or vacuum system shows up as underboost
• MAP sensor: an upgraded turbo can exceed the original MAP sensor threshold and report underboost when in fact boost is fine
• ECU map: if you have not remapped to match the new turbo, the ECU may be requesting boost levels the new turbo handles differently
• Wastegate / VNT actuator: mechanical issues with the vane control on VGT turbos

The diagnostic path is: check for boost leaks first, confirm the MAP sensor is within range, then bring the car to the tuner for a re-map and live data session.

If you cannot resolve it, email info@falconturbos.com with the car’s logs and the Falcon team will help diagnose.

My turbocharger leaks oil. What are the causes and solutions?

Oil leakage can have several causes, ranging from oil weeping at old gaskets to crankcase pressure issues, oil-line orientation, or installer error. A detailed guide covering each cause and its solution is coming soon.

In the meantime, if you are seeing oil leakage after fitting, contact info@falconturbos.com for an immediate diagnosis. Please include your order number, photos of where the oil is appearing, and a description of when it happens (cold start, under boost, idle).

My Falcon turbo is not performing as I expected. What should I do?

Sometimes the upgraded turbo performs below expectations for several common reasons:

• Torque limiter in the ECU is capping power below the turbo’s potential
• Incorrect pressures on the manifold
• Suboptimal map – in most cases this is fixable with a proper ECU tune

If a proper re-map does not resolve it, send your vehicle logs to info@falconturbos.com. The team can analyse the logs and advise on the next step.

What does black or white smoke after fitting mean?

• White smoke (mild, clears quickly): often residual oil burning off the new turbo on first runs, normal
• White smoke (persistent): possible coolant in the combustion chamber, head gasket issue unrelated to the turbo
• Blue smoke: oil burning – check breather system, oil return line angle, possible internal seal issue
• Black smoke: fuelling issue – more fuel than the turbo can support, needs re-map

Why does my turbo whistle or whine more than the factory unit?

Some additional noise is normal with an upgrade turbo. A Falcon BCW with a larger compressor wheel will inevitably make more induction noise under load than a worn factory unit. This is not a fault.

If the noise is a metallic rattle, a screech, or a knocking sound that comes and goes with boost, that is not normal – contact info@falconturbos.com with a short audio or video clip.

Contact & support

How do I get in touch?

• Email: info@falconturbos.com (best for technical questions with photos / logs)
• WhatsApp: +44 7932 301515 (fastest for quick fitment confirmation)
• Phone: 0114 232 0117 (business hours, 8:00 AM – 4:00 PM)
• Contact form: falconturbos.com/contact-us/

What are your response times?

Our typical response time during business hours (8:00 AM – 4:00 PM) is between 10 minutes and 2 hours. Response times may vary depending on enquiry volume, but we aim to reply as quickly as possible.

For urgent technical issues on a freshly fitted turbo, WhatsApp on +44 7932 301515 is usually the fastest route.

Where are you based?

Sheffield, UK. Falcon Turbo Developments Ltd, Unit 23, Nutwood Trading Estate, Limestone Cottage Lane, Sheffield S6 1NJ.

Do you offer fitting at your workshop?

We do not offer fitment of turbochargers. We can only recommend companies that do. We are working on a map of partner agents who can carry out fitting – so you will be able to find a recommended installer near you. No launch date yet, but it is on the roadmap.

Where can I see fitting manuals or video guides?

The Manuals page on the site lists current documentation: falconturbos.com/manuals/. The Falcon Turbos YouTube channel also has fitting videos and customer build features: youtube.com/@falconturbos