Car owners are likely to encounter a situation where the turbocharger is damaged and needs to be replaced. Below, we detail the steps to replace turbochargers.
STEP 1 - Clean the engine and replace the filter element
Drain the dirty oil, add 70% diesel and 30% engine oil to the engine, start the engine, run it for 3 to 5 minutes to clean the engine and oil passages, and then drain. Add an appropriate amount of engine oil and let it run after 5-10 minutes. Replace the oil filter element and the air filter element, then filter and add clean lubricating oil to the full scale of the oil dipstick to ensure that the engine lubricating oil and oil passages are clean.
STEP 2 - Check before replace turbocharger
Check whether the new turbocharger model matches the engine. Rotate the turbocharger rotor by hand. It should run smoothly. If the wheel is stagnant or has a feeling of rubbing against the casing, find out the reason before installing it.
Check whether there is debris in the compressor intake pipe and the engine exhaust pipe before the turbine to prevent the trash from damaging the impeller.
STEP 3 - Check the oil inlet pipe and return pipe of the turbocharger
The oil inlet and return pipes of the turbocharger should be clean, and the oil inlet and return pipes should not be twisted and blocked. If the oil inlet and return ports of the turbocharger use sealing gaskets, check whether the gaskets are corroded or deformed. The gaskets cannot stop the oil inlet and return ports.
STEP 4 - Replace turbocharger
The turbocharger is installed on the engine and is not connected to the oil pipe for the time being. First, add clean oil into the turbocharger from the oil inlet of the turbocharger. Turn the rotor by hand to fill the turbocharger bearing with lubricating oil before connecting the oil inlet pipe.
STEP 5 - Test run
After you replace tthe urbocharger, you can start the diesel engine. The oil pressure of the turbocharger oil inlet must be displayed within 3~4s to prevent the turbocharger bearing system from being damaged due to a lack of lubricating oil. Run for 2 minutes, check whether the rotor is rotating smoothly and without noise, then stop and observe whether the rotor can run smoothly by inertia. Usually, it will stop after about half a minute.
When the engine is running under load, the oil pressure must be between 196～392kPa to be safe, and when the engine is running at idle speed, the oil pressure should not be lower than 70kPa.
The exhaust backpressure behind the turbine and the pressure drop of the air filter must not exceed 4.9kPa. It would be best to protect the air filter element from moisture because the wet filter element will significantly increase the pressure drop.
Now you have done a good job to replace the turbocharger.
