Email: caeturbo@hotmail.com

TROUBLESHOOTING

Failure Symptoms and Possible Causes

  1. Boost pressure control swing valve/poppet valve does not close
  2. Dirty air filter system
  3. Dirty compressor or charge air cooler
  4. Engine air collector cracked/missing or loose gaskets
  5. Excessive flow resistance in exhaust system/ leakage upstream of turbine
  6. Foreign body damage on compressor or turbine
  7. Fuel system/injection feed system defective or incorrectly adjusted
  8. Insufficient oil supply of turbocharger
  9. Suction and pressure line distorted or leaking
  10. Turbine housing/flap damaged
  11. Turbocharger bearing damage
  12. Valve guide, piston rings, engine or cylinder liners worn/increased blow by

  1. Coke and sludge in turbocharger center housing
  2. Crankcase ventilation clogged and distorted
  3. Dirty air filter system
  4. Dirty compressor or charge air cooler
  5. Excessive flow resistance in exhaust system/ leakage upstream of turbine
  6. Oil feed and drain lines clogged, leaking or distorted
  7. Piston ring sealing defective
  8. Turbocharger bearing damage
  9. Valve guide, piston rings, engine or cylinder liners worn/increased blow by

  1. Dirty compressor or charge air cooler
  2. Engine air collector cracked/missing or loose gaskets
  3. Excessive flow resistance in exhaust system/ leakage upstream of turbine
  4. Exhaust gas leakage between turbine outlet and exhaust pipe
  5. Foreign body damage on compressor or turbine
  6. Insufficient oil supply of turbocharger
  7. Suction and pressure line distorted or leaking
  8. Turbine housing/flap damaged
  9. Turbocharger bearing damag

  1. Boost pressure control swing valve/poppet valve does not open
  2. Fuel system/injection feed system defective or incorrectly adjusted
  3. Pipe assy. to swing valve/poppet valve defective

  1. Foreign body damage on compressor or turbine
  2. Insufficient oil supply of turbocharger
  3. Turbine housing/flap damaged
  4. Turbocharger bearing damage

  1. Coke and sludge in turbocharger center housing
  2. Crankcase ventilation clogged and distorted
  3. Oil feed and drain lines clogged, leaking or distorted
  4. Piston ring sealing defective
  5. Turbocharger bearing damage
  6. Valve guide, piston rings, engine or cylinder liners worn/increased blow by

  1. Coke and sludge in turbocharger center housing
  2. Crankcase ventilation clogged and distorted
  3. Dirty air filter system
  4. Dirty compressor or charge air cooler
  5. Excessive flow resistance in exhaust system/ leakage upstream of turbine
  6. Oil feed and drain lines clogged, leaking or distorted
  7. Piston ring sealing defective
  8. Turbocharger bearing damage
  9. Valve guide, piston rings, engine or cylinder liners worn/increased blow by

  1. Boost pressure control swing valve/poppet valve does not close
  2. Dirty air filter system
  3. Dirty compressor or charge air cooler
  4. Engine air collector cracked/missing or loose gaskets
  5. Excessive flow resistance in exhaust system/ leakage upstream of turbine
  6. Foreign body damage on compressor or turbine
  7. Fuel system/injection feed system defective or incorrectly adjusted
  8. Insufficient oil supply of turbocharger
  9. Pipe assy. to swing valve/poppet valve defective
  10. Suction and pressure line distorted or leaking
  11. Turbine housing/flap damaged
  12. Turbocharger bearing damage
  13. Valve guide, piston rings, engine or cylinder liners worn/increased blow by

  1. Coke and sludge in turbocharger center housing
  2. Crankcase ventilation clogged and distorted
  3. Dirty air filter system
  4. Dirty compressor or charge air cooler
  5. Excessive flow resistance in exhaust system/ leakage upstream of turbine
  6. Oil feed and drain lines clogged, leaking or distorted
  7. Piston ring sealing defective
  8. Turbocharger bearing damage
  9. Valve guide, piston rings, engine or cylinder liners worn/increased blow by
Recommendations for Servicing and Care

The turbocharger is designed such that it will usually last as long as the engine. It does not require any special maintenance; and inspection is limited to a few periodic checks. To ensure that the turbocharger's lifetime corresponds to that of the engine, the following engine manufacturer's service instructions must be strictly observed:

  1. Oil change intervals
  2. Oil filter system maintenance
  3. Oil pressure control
  4. Air filter system maintenance

90 % of all turbocharger failures are due to the following causes:

  1. Penetration of foreign bodies into the turbine or the compressor
  2. Dirt in the oil
  3. Inadequate oil supply (oil pressure/filter system)
  4. High exhaust gas temperatures (ignition system/injection system)

These failures can be avoided by regular maintenance. When maintaining the air filter system, for example, care should be taken that no tramp material gets into the turbocharger.