This guide will walk you through replacing your malfunctioning turbocharger with a new one while also explaining what is causing the failure of your turbocharger. Before beginning, go through each step to make sure you have all the required materials and understand what you’ll be doing.
Table of Contents
Main Reasons for Turbocharger Failure
Make sure you comprehend the cause of the turbocharger failure before you loosen the nuts. Your turbocharger may be past its prime for one of four reasons:
1. Contaminated Oil
The journal bearings, turbine wheel shaft, and thrust components will deteriorate with the introduction of any pollutant, including carbon deposits and tiny pieces of metal from worn engine components. This frequently occurs in freshly rebuilt diesel engines because, during the rebuilding process, some metal particles can become lodged in the oil channels.
2. Damage By Foreign Objects
The air cleaner assembly may contain loose bolts or washers. Make sure the filters are sealed but not obstructed and that no hoses have holes.
3. Turbocharger Overspeed
Turbocharger overspeed may be caused by excessive fueling, improper turbocharger installation, a malfunctioning charge air system, or poor engine management. When a turbocharger is consistently run above its safe rotational speed, it is operating at overspeed. To avoid turbocharger overspeed in the future, double-check that all the hoses, gaskets, and piping between the input manifold and the turbocharger are installed correctly after installing a new turbocharger.
4. Insufficient Lubrication
The oil pressure at the engine and turbocharger should both be within the recommended ranges by the manufacturer. Carbon should not be added to the oil pickup screen. To guarantee the oil pressure remains at a sufficient level, the oil filters and oil supply line may need to be updated.
Prior To Starting
Reposition the bearing housing, compressor housing, and turbine housing if they are located other than where they were on the original turbocharger. Simply remove the bolts, circle between the end housings, or v-band nut, then carefully move the turbocharger. Make sure the housings are firmly in place without pinching the intake housing.
The v-band nut or nuts can be tightened and greased to the torque parameters advised by the manufacturer once the turbocharger has been installed and mounted to the engine.
Before replacing the turbocharger, the oil must also be drained. Run the engine for a few minutes to heat the oil and reduce viscosity in order to extract as much oil as workable. Be careful when removing the oil because it could be unsafe to touch it while it’s hot. If you’d like, you can use an engine, flush at this stage.
The old oil filter should be removed and replaced. We can then start the replacement process for the turbocharger.
Changing the Turbocharger
1. Remove every bolt holding the outdated turbocharger to the downpipes or exhaust pipe. Detach the pipes after removing the bolts holding the air intake system and turbocharger together.
2. Take the turbocharger intercooler apart, then use an oil degreaser to clean the interior. To ensure that the intercooler drains properly, flip it over and leave it there. This is an ideal opportunity to update your air filter if you need to.
3. Lift the turbocharger out of the engine compartment either through the top of it or from below by unscrewing the nuts and bolts, and holding it to the manifold.
4. Verify once more that the new turbocharger is positioned as the old one.
5. With the required nuts and bolts, start mounting the new turbocharger to the exhaust manifold. Adjust the torque according to the manufacturer’s instructions.
6. Everything you unplugged from the prior turbocharger should be reconnected. Start with the intercooler for the turbocharger. Reconnect the air intake system next. The exhaust downpipe comes last.
7. Replace the banjo bolts, copper washers that fit on the pipe’s ends, and oil feed pipe. Connect the new turbocharger’s oil feed pipe. To keep the components lubricated, squeeze a little engine oil into the turbo oil bay.
8. Your engine needs a new oil filter and oil.
9. Start the engine after finishing all the steps and let it run for ten seconds. Restrict engine revs. After those ten seconds, shut off the engine and look for leaks. You can recheck the oil level after a while.
10. The new turbocharger is all set!