Turbocharger Failure Diagnostic Checklist

Turbocharger Failure Diagnostic Checklist
 

The following list provides the most common symptoms related to turbocharger failure and possible causes. Before replacing your turbocharger look over the following checklist.


 

Engine running hot
 

  • Dirty Air Cleaner: Clean or replace element according to manufacturer’s recommendations.
  • Restricted compressor intake duct: Remove restriction or replace damaged parts as required.
  • Restricted air duct from compressor to intake manifold: Replace seals, gaskets or tighten fasteners as required.
  • Restricted intake manifold: Refer to engine manufacturer’s manual and remove restriction.
  • Air leak in feed from compressor to intake manifold: Replace seals, gaskets or tighten fasteners as required.
  • Air leak between intake manifold and engine: Refer to engine manufacturer’s manual and remove obstruction.
  • Restricted exhaust system: Remove restriction or replace damaged parts as required.
  • Failed diaphragm: Replace using correct actuator service kit.
  • Seized valve: Free valve/replace complete turbine housing sub-assembly.
  • Leaking hose: Replace hose and clips.
  • Wastegate mechanism set incorrectly: Get correct setting details.

 

Poor transient response
 

  • Dirty Air Cleaner: Clean or replace element according to manufacturer’s recommendations.
  • Restricted compressor intake duct: Remove restriction or replace damaged parts as required.
  • Restricted air duct from compressor to intake manifold: Replace seals, gaskets or tighten fasteners as required.
  • Restricted intake manifold: Refer to engine manufacturer’s manual and remove restriction.
  • Air leak in feed from compressor to intake manifold: Replace seals, gaskets or tighten fasteners as required.
  • Exhaust manifold cracked, gaskets blown or missing: Refer to engine manufacturer’s manual and replace gaskets or damaged parts as required
  • Gas leak at turbine inlet/exhaust manifold joint: Replace gasket or tighten fasteners as required.
  • Gas leak in ducting after turbine outlet: Refer to engine manufacturer’s manual and repair leak.
  • Fuel injection pump or fuel injectors incorrectly set: Refer to engine manufacturer’s manual and replace or adjust faulty components as required.
  • Seized valve: Free valve/replace complete turbine housing sub-assembly.
  • Wastegate mechanism set incorrectly: Get correct setting details.

 

Smoke
 

  • Dirty Air Cleaner: Clean or replace element according to manufacturer’s recommendations.
  • Restricted compressor intake duct: Remove restriction or replace damaged parts as required.
  • Air leak in feed from compressor to intake manifold: Replace seals, gaskets or tighten fasteners as required.
  • Air leak between intake manifold and engine: Refer to engine manufacturer’s manual and replace gaskets or tighten fasteners as required.
  • Exhaust manifold cracked, gaskets blown or missing: Refer to engine manufacturer’s manual and replace gaskets or damaged parts as required
  • Gas leak at turbine inlet/exhaust manifold joint: Replace gasket or tighten fasteners as required.
  • Fuel injection pump or fuel injectors incorrectly set: Refer to engine manufacturer’s manual and replace or adjust faulty components as required.
  • Wastegate mechanism set incorrectly: Get correct setting details.
     

Engine Lacks Power
 

  • Dirty Air Cleaner: Clean or replace element according to manufacturer’s recommendations.
  • Restricted air duct from compressor to intake manifold: Replace seals, gaskets or tighten fasteners as required.
  • Restricted intake manifold: Refer to engine manufacturer’s manual and remove restriction.
  • Air leak in feed from compressor to intake manifold: Replace seals, gaskets or tighten fasteners as required.
  • Air leak between intake manifold and engine: Refer to engine manufacturer’s manual and replace gaskets or tighten fasteners as required.
  • Foreign object in exhaust manifold (from engine): Refer to engine manufacturer’s manual and remove obstruction.
  • Restricted exhaust system: Remove restriction or replace damaged parts are required.
  • Exhaust manifold cracked, gaskets blown or missing: Refer to engine manufacturer’s manual and replace gaskets or damaged parts as required.
  • Gas leak at turbine inlet/exhaust manifold joint: Replace gasket or tighten fasteners as required.
  • Fuel injection pump or fuel injectors incorrectly set: Refer to engine manufacturer’s manual and replace or adjust faulty components as required
  • Engine valve timing incorrect: Refer to engine manufacturer’s manual for correct settings and adjust as required.
  • Worn engine piston rings or liners: Refer to engine manufacturer’s manual.
  • Burnt valves and/or pistons: Refer to engine manufacturer’s manual and repair as required.
  • Excessive dirt build-up on impeller and/or diffuser vanes: Clean in accordance with the appropriate repair manual.
  • Turbocharger damaged: Find and correct cause of failure, repair or replace turbocharger as necessary.
  • Wastegate mechanism set incorrectly: Get correct setting details. 
     

Black Exhaust Smoke

 

  • Dirty Air Cleaner: Clean or replace element according to manufacturer’s recommendations.
  • Restricted compressor intake duct: Remove restriction or replace damaged parts as required.
  • Restricted air duct from compressor to intake manifold: Replace seals, gaskets or tighten fasteners as required.
  • Restricted intake manifold: Refer to engine manufacturer’s manual and remove restriction.
  • Air leak in feed from compressor to intake manifold: Replace seals, gaskets or tighten fasteners as required.
  • Air leak between intake manifold and engine: Refer to engine manufacturer’s manual and remove obstruction.
  • Foreign object in exhaust manifold (from engine): Refer to engine manufacturer’s manual and remove obstruction.
  • Restricted exhaust system: Remove restriction or replace damaged parts as required.
  • Exhaust manifold cracked, gaskets blown or missing: Refer to engine manufacturer’s manual and replace gaskets or damaged parts as required.
  • Gas leak at turbine inlet/exhaust manifold joint: Replace gasket or tighten fasteners as required
  • Fuel injection pump or fuel injectors incorrectly set: Refer to engine manufacturer’s manual and replace or adjust faulty components as required.
  • Engine valve timing incorrect: Refer to engine manufacturer’s manual for correct settings and adjust as required.
  • Worn engine piston rings or liners: Refer to engine manufacturer’s manual.
  • Burnt valves and/or pistons: Refer to engine manufacturer’s manual and repair as required.
  • Excessive dirt build-up on impeller and/or diffuser vanes: Clean in accordance with the appropriate repair manual.
  • Turbocharger damaged: Find and correct cause of failure, repair or replace turbocharger as necessary. 

 

Blue Exhaust Smoke

 

  • Dirty Air Cleaner: Clean or replace element according to manufacturer’s recommendations.
  • Restricted compressor intake duct: Remove restriction or replace damaged parts as required.
  • Air leak in feed from compressor to intake manifold: Replace seals, gaskets or tighten fasteners as required.
  • Air leak between intake manifold from engine: Refer to engine manufacturer’s manual and remove obstruction.
  • Foreign object in exhaust manifold (from engine): Refer to engine manufacturer’s manual and remove obstruction.
  • Restricted turbocharger oil drain line: Remove restriction or replace damaged parts as required.
  • Restricted engine crankcase breather: Refer to engine manufacturer’s manual, clear restriction.
  • Turbocharger bearing housing sludged or coked: Change engine oil and oil filter, overhaul or replace turbocharger as required.
  • Worn engine piston rings or liners: Refer to engine manufacturer’s manual.
  • Burnt valves and/or pistons: Refer to engine manufacturer’s manual and repair as required.
  • Excessive dirt build-up on impeller and/or diffuser vanes: Clean in accordance with the appropriate repair manual.
  • Turbocharger damaged: Find and correct cause of failure, repair or replace turbocharger as necessary. 

     

High Oil Consumption
 

  • Dirty Air Cleaner: Clean or replace element according to manufacturer’s recommendations.
  • Restricted compressor intake duct: Remove restriction or replace damaged parts as required.
  • Air leak in feed from compressor to intake manifold: Replace seals, gaskets or tighten fasteners as required.
  • Air leak between intake manifold and engine: Refer to engine manufacturer’s manual and replace gaskets or tighten fasteners as required.
  • Foreign object in exhaust manifold (from engine): Refer to engine manufacturer’s manual and remove obstruction.
  • Restricted turbocharger oil drain line: Remove restriction or replace damaged parts as required.
  • Restricted engine crankcase breather: Refer to engine manufacturer’s manual, clear restriction.
  • Turbocharger bearing housing sludged or coked: Change engine oil and oil filter, overhaul or replace turbocharger as required.
  • Worn engine piston rings or liners: Refer to engine manufacturer’s manual.
  • Burnt valves and/or pistons: Refer to engine manufacturer’s manual and repair as required.
  • Excessive dirt build-up on impeller and/or diffuser vanes: Clean in accordance with the appropriate repair manual.
  • Turbocharger damaged: Find and correct cause of failure, repair or replace turbocharger as necessary.
     

Turbocharger Noisy
 

  • Restricted compressor intake duct: Remove restriction or replace damaged parts as required.
  • Restricted air duct from compressor to intake manifold: Replace seals, gaskets or tighten fasteners as required.
  • Restricted intake manifold: Refer to engine manufacturer’s manual and remove restriction.
  • Air leak in feed from air cleaner to compressor: Replace seals, gaskets or tighten fasteners as required.
  • Air leak in feed from compressor to intake manifold: Replace seals, gaskets or tighten fasteners as required
  • Air leak between intake manifold and engine: Refer to engine manufacturer’s manual and replace gaskets or tighten fasteners as required.
  • Foreign objects: Refer to engine manufacturers manual and remove obstruction.
  • Exhaust manifold cracked, gaskets blown or missing: Refer to engine manufacturers manual and replace gaskets or damaged parts as required.
  • Gas leak at turbine inlet/exhaust manifold joint: Replace gasket or tighten fasteners as required
  • Excessive dirt build-up on impeller and/or diffuser vanes: Clean in accordance with the appropriate repair manual.
  • Turbocharger damaged: Find and correct cause of failure, repair or replace turbocharger as necessary.
  • Failed diaphragm: Replace using correct actuator service kit.
  • Leaking hose: Replace hose and clips.
  • Wastegate mechanism set incorrectly: Contact nearest distributor for correct setting data.
     

Cyclic sound for turbocharger

 

  • Restricted compressor intake duct: Remove restriction or replace damaged parts as required
  • Excessive dirt build-up on impeller and/or diffuser vanes: Clean in accordance with the appropriate repair manual. 

 

Oil Leak from Compressor Seal

 

  • Dirty Air Cleaner: Clean or replace element according to manufacturer’s recommendations.
  • Restricted air duct from compressor to intake manifold: Replace seals, gaskets or tighten fasteners as required.
  • Restricted exhaust system: Remove restriction or replace damaged parts are required.
  • Exhaust manifold cracked, gaskets blown or missing: Refer to engine manufacturers manual and replace gaskets or damaged parts as required.
  • Restricted turbocharger oil drain line: Remove restriction or replace damaged parts as required.
  • Restricted engine crankcase breather: Refer to engine manufacturer’s manual, clear restriction.
  • Turbocharger bearing housing sludged or coked: Change engine oil and oil filter, overhaul or replace turbocharger as required.
  • Worn engine piston rings or liners: Refer to engine manufacturer’s manual.
  • Burnt valves and/or pistons: Refer to engine manufacturer’s manual and repair as required.
  • Excessive dirt build-up on impeller and/or diffuser vanes: Clean in accordance with the appropriate repair manual.
  • Turbocharger damaged: Find and correct cause of failure, repair or replace turbocharger as necessary.

 

Oil Leak from Turbine Seal
 

  • Restricted turbocharger oil drain line: Remove restriction or replace damaged parts as required.
  • Restricted engine crankcase breather: Refer to engine manufacturer’s manual, clear restriction.
  • Turbocharger bearing housing sludged or coked: Change engine oil and oil filter, overhaul or replace turbocharger as required.
  • Worn engine piston rings or liners: Refer to engine manufacturer’s manual.
  • Burnt valves and/or pistons: Refer to engine manufacturer’s manual and repair as required.
  • Excessive dirt build-up on impeller and/or diffuser vanes: Clean in accordance with the appropriate repair manual.
  • Turbocharger damaged: Find and correct cause of failure, repair or replace turbocharger as necessary. 
Source IPD


  • Posted on   10/29/15 at 04:13:36 PM   by Sara  | 
  • RSS
  • |
  • More

Reader Comments (0)

Comment Post Comment