Turbocharger Diagrams and Failure Analysis

 

Engine Lacks Power Black Exhaust Smoke Excessive Engine Oil Consumption Blue Exhaust Smoke Turbo Noisy Cyclic sound from turbo Oil Leak from compressor seal Oil Leak from turbine seal Cause                                Remedy                                  
* * * *     *    Clogged air filter Replace air filter                   
  * * * * * *   Obstructed air intake to turbo Remove Obstruction 
* *     *         Obstructed air outlet duct from  compressor to intake manifold Remove Obstruction  
* *     *       Obstructed intake Remove Obstruction
        *       Air leak in duct from air cleaner to compressor Replace seals or tighten fasteners
* * * * *       Air leak in duct from compressor to intake manifold Replace seals or tighten fasteners
* * * * *       Air leak at intake manifold to engine joint Replace seals or tighten fasteners
* * * * *   *   Obstruction in exhaust manifold Remove Obstruction
* *         *   Obstruction in muffler or exhaust stack Remove Obstruction
* *     *   *   Gas leak in exhaust manifold to engine joint Replace seals or tighten fasteners
* *     *   *   Gas leak in turbine inlet to exhaust manifold joint Replace seals or tighten fasteners
        *       Gas leak in ducting after turbine outlet Repair gas leak
    * *     * * Obstructed turbo oil drain line Remove obstruction or replace oil drain line
    * *     * * Obstructed engine crankcase vent Clear obstruction
    * *     * * Turbo center housing sledged or coked Change engine oil, filter, replace turbo as required
* *             Fuel injection pump or injectors incorrectly adjusted Replace or adjust injectors and/or injection pump
* *             Engine camshaft timing incorrect Check/reset timing
* * * *     * * Worn engine rings or liners (blowby) Repair as needed
* * * *     * * Internal engine problem (valves, pistons) Repair as needed
* * * * * * * * Dirt caked on compressor wheel Clean with non caustic cleaner and soft brush, change filters
* * * * * * * * Damaged turbo

Analyze turbo to determine failure, replace turbo
 
Turbocharger Installation Check List    
*

Replace oil supply lines and fittings.  These lines often become plugged with decomposed oil which restricts oil    flow and drainage.
*

Do not used silicone or thread tape
*

Make sure all openings to turbo are open and not plug or capped off.
*

Shut off fuel or disable ignition and crank the engine for at least 15 seconds or until oil pressure is raised
*

Allow engine to fast idle (1,000 RPM) for 3 – 5 minutes to seat turbo seals
* Always let engine idle for 3 -5 minutes before shut down, otherwise the turbo will continue to spin without oil  lubrication and pressure
* When changing oil, be sure to prime oil filter