How to Replace a Turbocharger in a Diesel Engine

1. Clean the engine and replace the filter element. Drain the dirty oil, add 70% diesel oil and 30% engine oil to the engine, start the engine and run for 3-5 minutes to clean the engine and oil passages, and then drain. Add an appropriate amount of oil, and drain it after running for 5-10 minutes. Replace the oil filter element and air filter element, and then filter and add clean lubricating oil to the full scale of the oil dipstick, so as to ensure that the engine lubricating oil and oil passages are clean.

2. Check the turbocharger. Check whether the new turbocharger model is compatible with the engine. Turn the turbocharger rotor by hand and it should run freely. If the impeller is stagnant or has a feeling of rubbing the casing, it is necessary to find out the reason and then install it.

3. Check whether there are debris in the compressor intake line and the exhaust line of the engine before the turbine to prevent debris from damaging the impeller.

4. Check the oil inlet and return pipes of the supercharger. The inlet and return oil pipes of the supercharger should be clean, and the inlet and return oil pipes should not be twisted and blocked. If the supercharger inlet and return oil ports use sealing gaskets, check whether the gaskets are corroded or deformed, and the gaskets cannot block the oil inlet and return ports.

5. Pre-lubricate the booster. The supercharger is installed on the engine, and the oil pipe is not connected temporarily. First, add clean oil into the supercharger from the oil inlet of the supercharger, and turn the rotor by hand to make the supercharger bearing full of lubricating oil, and then connect the oil inlet pipe. 

6. Trial operation. Start the diesel engine, and the oil inlet of the supercharger must show the oil pressure within 3 to 4s to prevent the supercharger bearing system from being damaged due to lack of lubricating oil. Run for 2 minutes, check whether the rotor rotates smoothly without noise, and then stop to observe whether the rotor can run smoothly by inertia. Normally, it stops after about half a minute.

8. When the engine is running under load, the oil pressure must be between 196 and 392kPa to be safe. When idling, the oil pressure should not be lower than 70kPa.

9. The exhaust back pressure after the turbine and the pressure drop of the air filter should not exceed 4.9kPa, and the air filter should avoid moisture, because the wet filter will significantly increase the pressure drop.

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