Clogged Air Filter Element

Obstructed air intake duct to turbo compressor

Obstructed duct from compressor to intake manifold

Obstructed intake manifold

Air leak in duct from air cleaner to compressor

Air leak in duct from compressor to intake manifold

Air leak at intake manifold to to engine juncture

Obstruction in exhaust manifold

Obstruction in muffler or exhaust system

Exhaust gas leak in exhaust manifold to engine juncture

Exhaust gas leak in exhaust manifold to turbine inlet

Exhaust gas leak in ducting after turbine outlet

Obstructed turbo oil drain line

Obstructed engine crancase vent

Turbocharger center housing coked or plugged up

Fuel injection pump or injectors incorrectly adjusted

Engine camshaft incorrectly timed

Blow-by (Worn piston rings and/or liners

Internal engine problems (pistons, valves, rods etc.)

Dirt caked on compressor wheel and/or diffuser area

Damaged turbocharger

Replace element according to engine manufacture’s specifications

Remove obstruction or replace dameaged parts as required

Remove obstruction or replace dameaged parts as required

Refer to engine manufactures maual and remove obstruction

Correct leak by replacing seals or tightening fasteners as required

Correct leak by replacing seals or tightening fasteners as required

Refer to manufactures maual and replace gaskets / tighten fasteners as required

Refer to engine manufacters manual and remove obstruction

Remove obstruction or replace faulty components as required

Refer to manufactures maual and replace gaskets / tighten fasteners as required

Replace gaskets or tighten fasteners as required

Refer to manufacturers manual and repair leak

Remove obstruction or replace oil line as required

Refer to engine manufacters manual and remove obstruction

Change engine oil and filter, overhaul or replace turbo as required

Refer to manufactures maual and replace faulty components as required

Refer to manufacturers manual and replace worn parts

Refer to manufacturers manual and repair engine as required

Refer to manufacturers manual and repair engine as required

Clean using non-caustic cleaner and soft brush, change oil, oil filter, and ir filter

Analyze failed turbo, find caus and correct, overhaul or replace turbo as required

Normal use and conitions

Contaminated oil, dirt in oil

Severely contaminated oil, dirty conditions

Pounded by eccentric shaft motion

Rough finish in center housing
Oil contaminated by metal or large particles

Lack of lube, oil lag, oil system failure

Coking from hot shutdowns

Fine particles in oil (contaminated oil)

Rough bearing journals on shaft

Acceptable operating and maitenance procedures are being followed

Engine oil/filters not changed on schedule, malfunction in filter by-pass/prelube valve

Engine oil/filters not changed on schedule, malfunction in filter by-pass/prelube valve

Imbalance, foreign object damage, coked/loose housing, excess bearing clearence

Incorrect cleaning of center housing during overhaul (wrong chemicals, bores blasted)
Severe engine wear, bearing damage, camshaft of lifter wear, broken pistons or rings

Low oil level, high speed shutdowns, lube system failure, turbo plugged with RTV

Hot shutdowns, engine overfueled, restricted or leaking air intake

Engine oil/filters not changed on schedule, malfunction in filter by-pass/prelube valve

Bearing journals not protected from sand or bead blast cleaning during overhaul

PROBABLE CAUSE

REMEDY

PROBABLE CAUSE

CONDITION

Injested Foreign Object

Damage (FOD)

• Engine Component Failure
• Slag/Weld Material From
Turbine Inlet System

• Broken/Bent Blades
• Excessive Turbine Inlet Temp
• Lubrication Failure

Structural Failure

Blades In Contact With Housing

• Improper Assembly
• Worn Bearings; Lubrication Failure
• Bent Wheel; Shaft Assembly
• Inadequate Housing Clearance
• Blade “Flowering”; Excessive Speed
and / or Temperature

• Out Of Balance
• Thrust Bearing Failure
On Compressor Side
• Loose Compressor Wheel

-Turbine Wheel Damage-

-Turbine Housing Failure-

• Excessive Turbine Inlet Temperature
• Turbine Wheel Contact / Failure
• Injected Foreign Material
• Corrosion
• Mounting Stress
• External Damage

-Compressor

Wheel

Damage-

Structural Damage

• Overspeed
• Broken Bent Blades
• Excessive Pressure Ratio

Blades In Contact w/Housing

• Thrust bearing failure
• Worn Bearings/Housings
• Bent Turbine Wheel

Compressor Wheel Loose On Shaft

• Back-fire (draw-through)
• High Pressure Decel Surge
• Housing Contact

• Incorrect Compressor Match
• Incorrect Turbine Match
• Excessive Boost Pressure
• Rapid Downstream Throttle Closure

• Lubrication Failure, Low Oil Pressure
• Contaminated Oil
• Foreign Material Clogging Oil Feed
• Bent Turbine Wheel
• Excessive Exhaust Backpressure
• Worn Thrust Collar

Compressor

-Thrust Failure-

• Lubrication Failure, Low Oil Pressure
• Contaminated Oil
• Foreign Material Clogging Oil Feed
• Bent Turbine Wheel
• Worn Thrust Collar
• Severe Compressor Surge
• Excessive Pressure Ratio At Inlet
• Rapid Throttle Closure At High Boost

Turbine

-Thrust Failure-

-Compressor Surge-

TURBO TROUBLESHOOTING

BEARING TROUBLESHOOTING

Turbine Seal Leaking Oil

Compressor Seal Leaking Oil

Lack Of Power In Engine

Exhaust Smoke (Black)

Excessive Oil Consumption

Exhaust Smoke (Blue)

Cyclic Sound From T

urbo

Excessive T

urbocharger Noise

BEARING APPEAREANCE

Deep Groove

Around Center of O.D.

Slight W

ear or Scratches

Moderate to Heavy Grooving On O.D. & I.D.

Cracked or Broken Bearings

PROBLEM

Melted (Aluminum Bearing)

I.D. Polished & W

orn Oversize

Polished Looking O.D.

Oil Holes Fully or Partially Closed

Oil Holes Plugged with Carbon

Extruded or Pounded (S

tuck In Housing)

Excessive Oil Consumption

Moderate T

o Heavy Grooving On O.D. Only