Turbocharger Components Failure Analysis
Diagnostics, Causes, Troubleshooting and Prevention of faults
Shortly about the most common injury patterns of the turbocharger and valuable advises about analysis of the cause, troubleshooting and prevention:
- Oil fouling in the bearing housing
- Oil sludge deposits in the oil line
- Oil flow due to clogged oil circulation line
- Compressor damage by foreign particles
- Compressor wheel damaged by foreign particles
- Cracks in the turbine housing​
- Turning marks on compressor impeller
- Damage of the turbine wheel edge by foreign particles
Oil fouling in the bearing housing
Symptoms
- Blue smoke
- Loss of power
- Turbine and compressor oil leakage
- Charge air cooler clogged
- Clogged exhaust gas aftertreatment device
Causes
- Use of unsuitable oil (low quality)
- Overheating of turbocharger
- Rapid shutdown of a hot engine
Troubleshooting / Prevention
- Observe the prescribed oil quality
- Leave the hot engine running for at least another minute
- Take the following measures into consideration during tuning
- Do not flush with oil until a defect in the turbocharger has been found so that no deposits can enter the lubrication system
- Dismantle and thoroughly clean the oil tank
Replace the turbocharger after you have flushed it with oil. - Follow the installation instructions.
Strictly observe oil change intervals when operating on biofuel - Change the oil more frequently when operating with biofuels
- When replacing the turbocharger, always change the oil and oil filter as well as the air filter
Oil sludge deposits in the oil line
Symptoms
- Blue smoke
- Loss of power
- Turbine and compressor oil leakage
- Charge air cooler clogged
- Clogged exhaust gas aftertreatment device
Causes
- Failure to observe oil change intervals
- Use of unsuitable oil (low quality)
- Improperly laid oil lines
- No thermal protection
Troubleshooting / Prevention
- When replacing the turbocharger, be sure to replace and properly route the oil lines
- Pay attention to the required quality and adhere to the specified change intervals
- If the turbocharger is damaged, the charge air cooler must be replaced
- If the turbine wheel is damaged, replace the dust filter and check the catalytic converter
- When replacing the turbocharger, be sure to change the oil and oil filter as well as the air filter
- Considerably reduce the frequency of oil changes when operating on biofuel
- Follow the installation instructions
Oil flow due to clogged oil circulation line
Symptoms
- Blue smoke
- Loss of power
- Engine oil pressurized in turbine and compressor
- Stiffness of mechanisms (adjustment, bypass, exhaust gas bypass valve)
- Severe contamination of the charge air cooler
- Trapped engine oil in charge air cooler
- Clogging of the exhaust gas aftertreatment device
Causes
- Restriction or bending of the circulation line
- The oil level in the engine is too high
- Use of sealant instead of gasket kit
- Circulation line replacement, but not replacing engine connection parts
Troubleshooting / Prevention
- Only use a suitable sealant installation kit
- Replace the oil pipes
- Thoroughly clean the circulation connections to the motor
- Dismantle and thoroughly clean the oil tank
- Thoroughly clean the charge air cooler or replace it if necessary
- When replacing the turbocharger, always change the oil and oil filter as well as the air filter
- Replace the turbocharger if the mechanism (variable geometry turbocharger, bypass, exhaust gas bypass valve) is blocked
- Significantly reduce oil change intervals when operating on biofuel
Compressor damage by foreign particles
Symptoms
- Blue smoke
- Loss of power
- Noise (whistling)
- Charge air cooler is clogged
Causes
- Restriction or bending of the circulation line
- The oil level in the engine is too high
- Use of sealant instead of gasket kit
- Circulation line replacement, but not replacing engine connection parts
Troubleshooting / Prevention
- Only use a suitable sealant installation kit
- Replace the oil pipes
- Thoroughly clean the circulation connections to the motor
- Dismantle and thoroughly clean the oil tank
- Thoroughly clean the charge air cooler or replace it if necessary
- When replacing the turbocharger, always change the oil and oil filter as well as the air filter
- Replace the turbocharger if the mechanism (variable geometry turbocharger, bypass, exhaust gas bypass valve) is blocked
- Significantly reduce oil change intervals when operating on biofuel
Compressor wheel damaged by foreign particles
Symptoms
- Blue smoke
- Loss of power
- Noise (whistling)
- Charge air cooling radiator clogged
Causes
- Molten sediment from the crankcase ventilation system
- Ice in the intake system
- Fragmentation of turbocharger with prior damage
- Abrasive wear of compressor blades
Troubleshooting / Prevention
- Thoroughly clean entire intake system
- Thoroughly clean or replace the crankcase ventilation system
- Replace turbocharger
- Read out the fault accumulator and check the air mass measuring device
- When changing the turbocharger, be sure to change the oil and oil filter and the air filter
- Clean the suction pipe
- Check the air intake system for leaks
Cracks in the turbine housing
Symptoms
- Power loss at low rpm
Causes
- Rapid shutdown of hot engine
- Overheating due to faulty injection system settings
- Improper boost
Troubleshooting / Prevention
- When replacing the turbocharger, be sure to change the oil and oil filter as well as the air filter
- Run the engine when it is hot for at least one minute
- Check the engine management system
Turning marks on compressor impeller
Symptoms
- Blue smoke
- Loss of power
- Increased back pressure
- Dirty air filter
Causes
- Bearing damage because of contaminated oil
- Bearing damage from not enough oil
- Sealant used instead of a gasket kit
- Circulation line has been replaced without replacing the motor connection
Troubleshooting / Prevention
- Check bearing play on the turbocharger shaft
- Check the condition of the motor oil and bleed the motor if necessary
- Check oil pressure
- When replacing the turbocharger, always change the oil and oil filter as well as the air filter
Damage of the turbine wheel edge by foreign particles
Symptoms
- Blue smoke
- Power loss
- Noises
- Severe contamination of the charge air cooler
- Clogged exhaust gas aftertreatment device
- Clogging of mechanisms (adjustment, bypass, exhaust gas bypass valve)
- Engine control system switches to the emergency mode program
Causes
- Foreign particles in the turbine through the engine
- Loose components in the exhaust manifold and exhaust gas aftertreatment
Troubleshooting / Prevention
- Endoscopic combustion chamber inspection
- Check exhaust gas aftertreatment for foreign particles and mechanical damage
- Check and if necessary replace all turbocharger piping
- Check and if necessary replace the charge air cooling radiator
- Check and if necessary replace compensator tubes and manifolds
- Replace the turbocharger
Afterword
This brings our article to an end. If you are interested in equipment for the turbocharger repair, you can contact our experts for advice. They will be happy to offer you the best set of equipment for you. Thank you for your attention and good luck in your work.
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