If your turbocharger is dying and you have some extra time to save some money and tackle the project yourself, you have come to the right place. This guide can help you understand why your turbocharger may be failing and then walk you through the steps to replace your faulty turbocharger with a new one. Read through all the steps before you dive in to make sure you have all necessary parts and understand what you’ll be doing.
Main Causes of Turbocharger Failure
Before you start loosening the bolts on your turbocharger, you will want to make sure you understand why the turbocharger failure has occurred. There are four reasons why your turbocharger may be at the end of its life:
- Contaminated oil - Any kind of contaminant entering the oil, from small bits of metal from worn engine parts to carbon deposits, will start to wear on the journal bearings, turbine wheel shaft, and thrust components. This is common in newly rebuilt diesel engines because some metal fragments may have lodged into the oil galleries during the rebuilding process. Oil contamination can also occur if the engine is overheated, if the engine has failed, or if the engine has not been serviced regularly.
- Damage From Foreign Objects - Loose bolts or washers may be present in the air cleaner assembly. Check the air cleaner assembly and all of the air induction piping to the turbocharger to ensure the filters are sealed but not blocked and that none of the hoses have perforations.
- Turbocharger Overspeed - Over fueling, incorrect turbocharger installation, a faulty charge air system, or faulty engine management can all contribute to turbocharger overspeed. Turbocharger overspeed is when the turbocharger is run continuously well beyond its safe rotational speed. Once you install a new turbocharger, be sure that all the hoses, gaskets, and piping between the inlet manifold and the turbocharger are all properly installed to prevent future turbocharger overspeed.
- Inadequate Lubrication - The oil pressure at both the turbocharger and engine should be within the manufacturer's specifications. The oil pickup screen should not be built up with carbon (and therefore decreasing the oil flow). The oil filters and oil supply line may need to be replaced to ensure the oil pressure to the turbocharger remains at an adequate level.
Before you Begin
After you find a suitable turbo for sale, you'll have to make sure the parts are positioned correctly. If the bearing housing, compressor housing, and turbine housing are positioned differently than your original turbocharger, you will want to reorient them to match the original turbocharger. Simply loosen the v-band nut, bolts, or circle between the end housings and reposition the turbocharger carefully. Do not pinch the intake housing but do make sure the housings are firmly in place.
When the turbocharger has been installed and mounted to the engine, the v-band nut or bolts can be tightened and lubricated to the torque specifications recommended by the manufacturer.
You will also need to drain the oil prior to replacing the turbocharger. To get as much oil out as possible, run the engine for a few minutes to heat the oil, so the viscosity is lower (which will allow more oil to drain from the engine). Handle the oil removal process carefully as the hot oil could be dangerous if touched. You can also utilize an engine flush at this step if you wish.
Remove and replace the old oil filter. Then, you are ready to begin the steps for replacing the turbocharger.
Replacing the Turbocharger
- To replace an old turbocharger, you need to remove it first. Unscrew all the bolts that link the old turbocharger to the downpipes (also known as the exhaust pipe). Remove the bolts that connect the air intake system to the turbocharger as well and then detach the piping.
- Remove the turbocharger intercooler and clean the inside with an oil degreaser. Invert the intercooler and leave it that way so it can drain properly. If your air filter needs to be replaced, now is a great time to do that.
- Unscrew the nuts and bolts that hold the turbocharger and the manifold together, then lift the turbocharger either out through the top of the engine compartment or below it.
- Confirm again that the new turbocharger is aligned the same way the old one was.
- Begin attaching the new turbocharger to the exhaust manifold with the necessary nuts and bolts. Tighten it to the torque suggested in the manufacturer's guide.
- Reconnect everything you disconnected from the previous turbocharger. Start with the turbocharger intercooler. Next, reattach the air intake system. Finish with the exhaust downpipe.
- The banjo bolts, oil feed pipe, and copper washers that fit on either end of the pipe should be replaced. Connect the oil feed pipe to the new turbocharger. Squeeze some engine oil into the turbo oil bay to keep the parts lubricated.
- Replace a new oil filter and oil into your engine.
- Once you have completed all the steps, start the engine and let it run for ten seconds. Do not rev the engine. Turn off the engine after those ten seconds and check for any leaks. After a few minutes, you can recheck the oil level. Top it off if necessary.
- Enjoy your new turbocharger!
We have many different turbochargers for sale, including new, used, and rebuilt turbochargers. For any and all diesel engine parts you need, check out our inventory online.
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Replacing a turbocharger is a fairly easy task anyone could take on. If you have some extra time on your hands and want to save money, we have this guide you can follow. It is easy and quick. Plus, it includes a step-by-step walkthrough and a preparatory manual to get you started. Keep on reading.
