Turbo

KOLBENSCHMIDT PIERBURG
50 003 973-02 03/05

MSI Motor Service
International GmbH
Untere Neckarstrae
D-74172 Neckarsulm
Phone +49 71 32-33 33 33
Fax +49 71 32-33 28 64
Hamburger Strae 15
D-41540 Dormagen
Phone +49 21 33-2 67-100
Fax +49 21 33-2 67-111
info@msi-motor-service.com
www.msi-motor-service.com
TURBOCHARGER
TROUBLE SHOOTING AND DAMAGE ANALYSIS
TABLE OF CONTENTS
PAGE 1 -
PAGE 2 -
PAGE 3 -
PAGE 4 - 6 -
PAGE 7 -
PAGE 8 - 9 -
PAGE 10 -
PAGE 11 - 12 -
PAGE 13 -
PAGE 14 - 15 -
PAGE 16 - 17 -
PAGE 18 - 19 -

TITLE PAGES (FRONT PAGES)
TABLE OF CONTENTS
INTRODUCTION
DESIGN AND FUNCTION OF A TURBOCHARGER
TROUBLE SHOOTING CHART
DAMAGE TO EXHAUST TURBINE BLADE
DAMAGE TO EXHAUST TURBINE AND COMPRESSOR WHEEL BLADES
DAMAGE TO THE COMPRESSOR WHEEL BLADES
DAMAGE CAUSED BY A LOOSE COMPRESOR WHEEL NUT
DAMAGE DUE TO LACK OF LUBRICANT / HOT SHUT DOWN
BEARING WEAR DUE TO OIL CONTAMINATION
SUMMARY

50 003 973-02 03/05
MSI Motor Service
International GmbH
Untere Neckarstrae
D-74172 Neckarsulm
Phone +49 71 32-33 33 33
Fax +49 71 32-33 28 64
Hamburger Strae 15
D-41540 Dormagen
Phone +49 21 33-2 67-100
Fax +49 21 33-2 67-111
If the engine does not operate properly, one should not assume that the turbocharger is the cause of
failure.
It often happens that fully functioning turbochargers are replaced even though the failure does not lie
here, but with the engine.
A faulty turbo can cause low power, black smoke, excessive oil consumption, oil in the intake, oil in the
exhaust as well as other problems.
To determine if the turbo is the problem an inspection of the shaft assembly can be made. Remove the
intake and / or exhaust plumbing to the turbo. Look for any evidence that the wheel has toughed or rubbed
the housing. If no signs are evident physically push the wheel to one side and see if the wheel can be made
to contact the housing. If either of these conditions exist the turbo should be repaired or replaced. If the
shaft is tight and wheels have not rubbed other checks should be made before replacing the turbo.
What is good for a turbocharger?
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 engine manufacturer's
service instructions must be strictly observed:
Oil change intervals
Oil filter system maintenance
Oil pressure control
Air filter system maintenance
What is bad for a turbocharger?
90 % of all turbocharger failures are due to the following causes:
Penetration of foreign bodies into the turbine or the compressor
Dirt in the oil
Inadequate oil supply (oil pressure/filter system)
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.
INTRODUCTION
50 003 973-02 03/05
MSI Motor Service
International GmbH
Untere Neckarstrae
D-74172 Neckarsulm
Phone +49 71 32-33 33 33
Fax +49 71 32-33 28 64
Hamburger Strae 15
D-41540 Dormagen
Phone +49 21 33-2 67-100
Fax +49 21 33-2 67-111
EXHAUST GAS TURBOCHARGING
The turbocharger is bolted to the exhaust manifold of the engine.
The exhaust gases from the cylinders passes through the turbine blades, causing it to spin. The more exhaust gases
going through the blades, the faster the turbine wheel will spin.
The turbine wheel is connected by a shaft to the compressor wheel, which is located between the air filter and the intake
manifold. The compressor wheel pressurizes the air going into the intake to wards the pistons.

The compressor is a type of centrifugal pump; it draws air in at the center of its blades and flings it outward as it spins.
In order to handle speeds of up to 150,000 RPM, the turbine shaft has to be supported very carefully. Most bearings
would explode at speeds like this, so most turbochargers use a fluid bearing.
This type of bearing supports the shaft on a thin layer of oil that is constantly pumped around the shaft.
This is also to :
1. Cools the shaft and some of the other turbocharger parts
2. Allows the shaft to spin without much friction
Compressor
wheel
Compressor
Ambient air
inlet
Compressor air
discharge
Turbine exhaust gas inlet
Turbine wheel
TURBINE
SECTION
Turbine exhaust gas outlet
Compressor housing
Turbine housing
COMPRESSOR
SECTION
1
7
50 003 973-02 03/05
MSI Motor Service
International GmbH
Untere Neckarstrae
D-74172 Neckarsulm
Phone +49 71 32-33 33 33
Fax +49 71 32-33 28 64
Hamburger Strae 15
D-41540 Dormagen
Phone +49 21 33-2 67-100
Fax +49 21 33-2 67-111
TURBO PARTS
50 003 973-02 03/05
MSI Motor Service
International GmbH
Untere Neckarstrae
D-74172 Neckarsulm
Phone +49 71 32-33 33 33
Fax +49 71 32-33 28 64
Hamburger Strae 15
D-41540 Dormagen
Phone +49 21 33-2 67-100
Fax +49 21 33-2 67-111
Turbocharger with twin-entry turbine Turbocharger with water-cooled turbine housing
1. Compressor Inlet
2. Compressor Discharge
3. Charge air cooler (CAC)
4. Intake Valve
5. Exhaust Valve
6. Turbine Inlet
7. Turbine Discharge
Schematic of an exhaust gas turbocharged four-cylinder
1 7
6
2
3
4
5
50 003 973-02 03/05
MSI Motor Service
International GmbH
Untere Neckarstrae
D-74172 Neckarsulm
Phone +49 71 32-33 33 33
Fax +49 71 32-33 28 64
Hamburger Strae 15
D-41540 Dormagen
Phone +49 21 33-2 67-100
Fax +49 21 33-2 67-111
OIL LEAKAGE AT TURBINE
OIL LEAKAGE AT COMPRESSOR END
HIGH OIL CONSUMPTION

TURBOCHARGER GENERATES ACOUSTIC NOISE
BLUE SMOKE

BLACK SMOKE
BOOST PRESSURE TOO HIGH
INSUFFICIENT POWER / BOOST PRESSURE TOO LOW

COMPRESSOR / TURBINE WHEEL DAMAGED

POSSIBLE CAUSES

DIRTY AIR FILTER SYSTEM

INTAKE OR PRESSURE HOSE DISTORTED AND / OR LEAKING
EXCESSIVE FLOW RESISTANCE IN EXHAUST SYSTEM /
LEAKING UPSTREAM OF TURBINE

OIL FEED AND / OR DRAIN LINES CLOGGED, LEAKING OR
DISTORTED

CRANKCASE VENTILATION CLOGGED AND / OR DISTORTED
OIL COKED OR SLUDGE IN TURBOCHARGER CENTER HOUSING
FUEL SYSTEM / INJ ECTION FEED SYSTEM DEFECTIVE OR
INCORRECTLY ADJ USTED

VALVE GUIDE, PISTON RINGD, ENGINE OR CYLINDER LINERS
WORN / INCREASED BLOW BY

DIRTY COMPRESSOR OR CLOGGED INTERCOOLER
BOOST PRESSURE CONTROL SWING VALVE/ POPET VALVE
DOES NOT CLOSE

BOOST PRESSURE CONTROL SWING VALVE/ POPET VALVE
DOES NOT OPEN

PIPE OR HOSE ASSY. TO ACTUATOR VALVE DEFECTIVE OR
RUPTURED

COMPRESSOR OR TURBINE END SEALING RINGS DAMAGED
TURBOCHARGER BEARING DAMAGED
FOREIGN OBJ ECT DAMAGED TO COMPRESSOR OR TURBINE
WHEEL

EXHAUST GAS LEAK BETWEEN TURBINE OUTLET AND
EXHAUST PIPE

ENGINE AIR COLLECTOR / CLEANER MISSING OR LOOSE
GASKET

TURBINE HOUSING / FLAP DAMAGED
INSUFFICIENT OIL SUPPLY TO TURBOCHARGER
TURBO VARIABLE RING MECHANISM INOPERABLE OR
DAMAGED

PROBLEM DECRIPTION
TROUBLE SHOOTING CHART
50 003 973-02 03/05
MSI Motor Service
International GmbH
Untere Neckarstrae
D-74172 Neckarsulm
Phone +49 71 32-33 33 33
Fax +49 71 32-33 28 64
Hamburger Strae 15
D-41540 Dormagen
Phone +49 21 33-2 67-100
Fax +49 21 33-2 67-111
CONDITION
Piece of the blades broke
Fines polished marks visible on housing and blades
Aluminum remnants on the blades and other parts of the wheel
DAMAGE
Damage to the turbine wheel is cause either by foreign objects being expelled from the motor through the
cylinder head ports
A hard foreign object entering the turbine will damage the blades as shown.
Even small objects such as rust scale (from the exhaust manifold) can cause considerable damage to
such high speed components.
POSSIBLE CAUSES
Particles of the broken injector tip
Aluminum particles of the piston or aluminum cylinder head.
Broken particles valve seat ring.
Broken particles valve.
Foreign particles
RECOMMENDATION
Do not reuse.
Determine the reason for foreign objects entering the turbocharger before replacement with a new
assembly.
Check and repair the engine, check the exhaust manifold for foreign or aluminum particles examined and
cleaned or replaced accordingly!
Deposits on the turbine wheel Piece of the blades broken
50 003 973-02 03/05
MSI Motor Service
International GmbH
Untere Neckarstrae
D-74172 Neckarsulm
Phone +49 71 32-33 33 33
Fax +49 71 32-33 28 64
Hamburger Strae 15
D-41540 Dormagen
Phone +49 21 33-2 67-100
Fax +49 21 33-2 67-111
Exceptional Operating Conditions
CONDITION
Blades are melted and potions of the blades is missing.
Wheel broken in pieces.
Shaft is coke.
Turbine wheel back is concave.
DAMAGE
Typical damage is high temperature at bearing journals, on sever examples, the oil burns and "cokes"
the shaft.
Often the back face of the turbine wheel is slightly concave, usually accompanied by an "orange peel"
effect on the back face of the compressor wheel.
Over speeding can also cause the loss of a portion of the blades.
In extreme cases, the wheel can burst due to over speeding.
POSSIBLE CAUSES
Over Speeding.
Over Boosting.
Excessive Temperature.
RECOMMENDATION
Do not reuse.
Determine the reason for the over speeding before replacement with a new assembly.
Concave back face
Portion of the blades missing and melted
Oil burns and "cokes" the shaft.
Burst due to over speeding
50 003 973-02 03/05
MSI Motor Service
International GmbH
Untere Neckarstrae
D-74172 Neckarsulm
Phone +49 71 32-33 33 33
Fax +49 71 32-33 28 64
Hamburger Strae 15
D-41540 Dormagen
Phone +49 21 33-2 67-100
Fax +49 21 33-2 67-111
DAMAGE TO EXHAUST TURBINE AND
COMPRESSOR WHEEL BLADES
CONDITION
The turbine wheel blades and turbine housing are worn (360 degrees).
Fines polished marks visible.
DAMAGE
The turbine blade made contact against the turbine housing due to the shaft bearing failure.
POSSIBLE CAUSES
Shaft bearings worn.
Thrust washer worn.
RECOMMENDATION
Do not reuse.
Determine the reason for bearing failure.
Determine the cause of insufficient lubrication to the turbocharger.
The unbalanced condition can be the result of excessive material removal.
Contact against the housing Polished marks / Worn blades
EXHAUST TURBINE WHEEL
COMPRESSOR WHEEL
COMPRESSOR WHEEL HOUSING
50 003 973-02 03/05
MSI Motor Service
International GmbH
Untere Neckarstrae
D-74172 Neckarsulm
Phone +49 71 32-33 33 33
Fax +49 71 32-33 28 64
Hamburger Strae 15
D-41540 Dormagen
Phone +49 21 33-2 67-100
Fax +49 21 33-2 67-111
FOREIGN OBJECT DAMAGE
CONDITION
Compressor wheel blade are worn.
Damage blades with pieces missing.
DAMAGE
This damage was caused by a foreign object entering the compressor. The object may bounce around in
the compressor inlet causing the damage seen. Dirt or dust causes severe damage to blades, eventually
leading to blade failures. this will result in poor engine performance and black smoking.
POSSIBLE CAUSES
Foreign particles in inlet pipe between air filter and turbo when replacing the turbo.
Leaking air intake system.
Damaged air filter.
RECOMMENDATION
Do not reuse.
Check the complete air intake system, air inlet adapters, air cleaner for the source of dust / dirt entry.
Smaller particle
Large particles
50 003 973-02 03/05
MSI Motor Service
International GmbH
Untere Neckarstrae
D-74172 Neckarsulm
Phone +49 71 32-33 33 33
Fax +49 71 32-33 28 64
Hamburger Strae 15
D-41540 Dormagen
Phone +49 21 33-2 67-100
Fax +49 21 33-2 67-111
SOFT FOREIGN OBJECT DAMAGE
CONDITION
Compressor wheel blade are bend.
Pieces of the bend blades can be missing.
DAMAGE
This damage was caused by a soft foreign objects such as workshop cloths or even paper wipes can
cause the damage. Typically, the blades bend backwards and in extreme cases sections of the blade
may break away due to metal fatigue.
POSSIBLE CAUSES
Soft foreign object was left in the inlet pipe between air filter and turbo.
The paper material from the damaged air filter.
RECOMMENDATION
Do not reuse.
Check the complete air intake system, air inlet adapters, air cleaner for the source of entry.
50 003 973-02 03/05
MSI Motor Service
International GmbH
Untere Neckarstrae
D-74172 Neckarsulm
Phone +49 71 32-33 33 33
Fax +49 71 32-33 28 64
Hamburger Strae 15
D-41540 Dormagen
Phone +49 21 33-2 67-100
Fax +49 21 33-2 67-111
DAMAGE CAUSED BY A LOOSE COMPRESOR
WHEEL NUT
CONDITION
Compressor wheel spun on shaft.
DAMAGE
This compressor wheel lock nut came loose and spun on the shaft.
It is also possible that the compressor wheel blade will make contact against the compressor housing.
POSSIBLE CAUSES
Loose compressor wheel lock nut from improper assembly.
RECOMMENDATION
Do not reuse.
Review proper assembly technique as outlined in the service manual.
Note: Never reuse compressor wheel or lock nut.
50 003 973-02 03/05
MSI Motor Service
International GmbH
Untere Neckarstrae
D-74172 Neckarsulm
Phone +49 71 32-33 33 33
Fax +49 71 32-33 28 64
Hamburger Strae 15
D-41540 Dormagen
Phone +49 21 33-2 67-100
Fax +49 21 33-2 67-111
DAMAGE DUE TO LACK OF LUBRICANT
/ HOT SHUT DOWN
CONDITION
Characterized by extreme discolouring of shaft journals
Blue shaft with score marks.
DAMAGE
Any lack of lubrication will result in heat marks on the turbine shaft. A lack of oil will turn the shaft blue and
make score marks in it.
Marginal Lubrication is when the oil supply to the turbo is reduced, (for instance when gasket materials
partially block an oil way or inlet flange).
Chemical Contamination causes heavy wear of bearing / shaft and excessive temperature. The visual
indications are very much the same as for marginal lubrication. The most common cause is dilution of oil
by fuel, reducing the lubricating properties of the oil.
Total Lack of Lubrication for similar causes, will show similar damage, but more extreme. Damage
happens very rapidly!
Damage from hot shut down will appear as a lack of lubrication. If you are under full boost, the turbo will
be spinning close to 100,000 rpm. If the motor is shut down the turbo is still spinning at extremely high
speed with no oil pressure.
Shutting down a glowing hot turbo with out allowing time for it to cool down will cause coking (excess
carbon deposits) that will block oil supply.
POSSIBLE CAUSES
Insufficient lubrication.
Bent oil feed line
Blockage of feed line
Defective oil pump etc
RECOMMENDATION
Do not reuse.
To prevent hot shut down damage, use a turbo timer to cool your turbo down.
Check oil feed and drain ports for blockages.
CARBON DEPOSITS BLOCKING OIL GALLERIES
Possible causes:
Incorrect oil specification
Exceed oil change intervals
50 003 973-02 03/05
MSI Motor Service
International GmbH
Untere Neckarstrae
D-74172 Neckarsulm
Phone +49 71 32-33 33 33
Fax +49 71 32-33 28 64
Hamburger Strae 15
D-41540 Dormagen
Phone +49 21 33-2 67-100
Fax +49 21 33-2 67-111
DAMAGE DUE TO LACK OF LUBRICANT
/ HOT SHUT DOWN
50 003 973-02 03/05
MSI Motor Service
International GmbH
Untere Neckarstrae
D-74172 Neckarsulm
Phone +49 71 32-33 33 33
Fax +49 71 32-33 28 64
Hamburger Strae 15
D-41540 Dormagen
Phone +49 21 33-2 67-100
Fax +49 21 33-2 67-111
CONDITION
Worn to a taper on the outside diameter.
Polishing of the bearing surface.
Rounding of the outer edges.

DAMAGE
Chemical Contamination causes heavy wear of bearing, shaft and causes excessive temperature.
The visual indications are same as for Marginal Lubrications.
Fine Particle Contamination may not be noticed in oil visually, but causes polishing of the bearing
surface and tell tale rounding of the outer edges. Often the compressor end bearing may be worn to a
taper on the outside diameter.
POSSIBLE CAUSES
The most common cause is dilution of oil by fuel, reducing the lubrication properties of oil.
Fine dirt in the oil.
RECOMMENDATION
Do not reuse.
Determine the reason for the fuel dilution in the oil before replacement with a new assembly
Determine the reason for the oil contamination due to dirt before replacement with a new assembly.
FUEL DILUTION
Rounding of the outer edges
Polishing of the bearing surface
Worn to a taper on the
outside diameter
RADIAL WEAR TO HALF BEARING RADIUS AND BEARING
Possible causes:
Un-permissive shaft run-out
Exceeding permissible unbalance
Unbalance due to large amount of carbon deposits
50 003 973-02 03/05
MSI Motor Service
International GmbH
Untere Neckarstrae
D-74172 Neckarsulm
Phone +49 71 32-33 33 33
Fax +49 71 32-33 28 64
Hamburger Strae 15
D-41540 Dormagen
Phone +49 21 33-2 67-100
Fax +49 21 33-2 67-111
CONDITION
Bearing bore scored and worn.
Deep scoring marks on the bearing surface.

DAMAGE
Contamination of oil with large particles, may cause impact damage and deep scoring.
The bearing bore may also be scored, usually to a lesser extent. The shaft and center housing are
usually damaged slightly less, being harder materials.
POSSIBLE CAUSES
The oil is contaminated with dirt.
Oil carbonization due to excessive heat
Exceed oil change intervals
RECOMMENDATION
Do not reuse.
Determine the reason for the oil contamination before replacement with a new assembly.
LARGE PARTICLE
The scoring shown was caused by oil contaminations.
50 003 973-02 03/05
MSI Motor Service
International GmbH
Untere Neckarstrae
D-74172 Neckarsulm
Phone +49 71 32-33 33 33
Fax +49 71 32-33 28 64
Hamburger Strae 15
D-41540 Dormagen
Phone +49 21 33-2 67-100
Fax +49 21 33-2 67-111
CAUSES OF TURBOCHARGER FAILURES
Approximately 40% of all turbocharger failures are oil-related.
Contaminated or dirty oil leads to bearing scratching and scoring which cause excessive bearing wear
and premature bearing failure. Another oil-related turbocharger failure is lack of lubrication.
As mentioned earlier, the turbo runs at very high speeds. Without full oil pressure to the turbocharger
bearings, even a momentary loss of oil pressure can quickly cause overheating and destroy the bearing
system. Lack of lubrication results not only from low oil pressure, but also from kinks and/or clogs in the
oil inlet line.
Occasionally, gasket sealant used between the oil inlet hose and the bearing housing seeps and clogs
the oil passages.
Another cause of turbocharger failures is inlet restrictions from plugged air cleaners, collapsing hose
connections or undersized air pipes. These restrictions reduce the air supply to the turbo and ultimately
to the engine resulting in excessive exhaust temperatures leading to turbine housing cracking and
scaling or even turbine wheel failures.
Inlet restrictions also can produce a vacuum inside the compressor. This can cause over speed
conditions in the turbo which can lead to premature bearing failure or even make a compressor wheel
burst. This vacuum inside the compressor also can cause oil leakage into the compressor.
The turbo's oil seals depend upon a positive air pressure inside the compressor and turbine to "push"
the oil inside the bearing housing and keep oil from seeping into the outer housings. In an inlet
restriction situation, the vacuum wants to "pull" the oil past the oil seals.
Prolonged oil leakage into the compressor can lead to oil seal damage and excessive engine smoking
Prolonged engine idling also can cause turbocharger oil seal failure, this time on the turbine side.
Continued idling causes the turbo to rotate without producing boost. Consequently, a vacuum condition
on the turbine side tries to "pull" oil past the turbine-side oil seal and into the turbine housing.
SUMMARY
CAUSES OF TURBOCHARGER FAILURES
Over-fueling also can lead to premature turbo failure by producing excessive exhaust temperatures
which can cause turbine housing scaling and cracking. As the turbine housing continues to deteriorate
from the excessive heat, pieces of the housing can crack off and cause turbine wheel failure.
Hot engine shutdown also can lead to turbocharger oil leakage by causing the oil to coke up inside the
oil drain and forcing the oil out the turbine and compressor seals. A clogged or collapsed oil outlet hose
also can cause oil to leak.
Another common cause of turbo failures is foreign object damage to either the compressor or turbine
wheels. A rapidly rotating wheel quickly disintegrates when a foreign body tries to pass through the
wheel's blades. This type of turbine wheel damage is the result of pieces of burned or broken valves
and combustion cups passing through the exhaust system.
Other turbine damage is due to casting flash that may break out of the manifolds and ports.
Occasionally improperly installed gaskets will allow pieces of the gasket to overhang a port and break
off into the exhaust system.
Damage caused by nuts and washers that are dropped into the exhaust system is also very frequent.
Scuffed and broken pistons often find their way out of the engine and into the turbocharger turbine
wheel.
Compressor wheel breakage also can occur from foreign object material although not as frequently as
turbine wheel damage. Sometimes pieces of the air cleaner will break loose and go through the
compressor. There also have been instances where hose connections fail and pieces of rubber or wire
reinforcing from the hose get into the compressor wheel. Again, carelessness in allowing nuts, bolts,
washers, rocks, rags and even screwdrivers to get into the intake systems will cause compressor wheel
failures.
SUMMARY

Turbo

Încărcat de

Informații document

Descriere originală:

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Turbo

Încărcat de

Drepturi de autor:

Formate disponibile

KOLBENSCHMIDT PIERBURG

50 003 973-02 03/05

S-ar putea să vă placă și