TURBOCHARGER DAMAGE

DIAGNOSIS, PROBABLE CAUSES, REMEDY AND PREVENTION

At a glance: the most common turbocharger damage profiles along with valuable, practical tips on analysing their causes as well as remedying
and preventing the damage.
FINDING

EFFECTS

PROBABLE CAUSES

REMEDY/PREVENTION

Oil carbon in
bearing case

n 

Blue-smoke
n L
oss of performance
n L
oss of oil via turbine and compressor
n C
 ontamination in the charge-air cooler
n C
 logged exhaust gas cleaning system
n B
 locked control mechanism with
adjustable turbochargers

n 

Use of unsuitable engine oil

(poor quality)
n T
urbocharger overheating
n I
mmediate switch off of the hot engine

n 

Oil carbon
deposits in
oil pipe

n 

Blue-smoke
n L
oss of performance
n T
otal failure of the turbocharger
n H
 eavy contamination of the charge-air
cooler with foreign bodies
n C
 logged exhaust gas cleaning system
n T
urbocharger makes a lot of noise

n 

Overdue oil change interval

n U
 se of unsuitable engine oil
(poor quality)
n I
ncorrectly laid oil pipe
n M
 issing heat shield

n 

Oil consumption
through clogged
oil return pipe

n 

Blue-smoke
n L
oss of performance
n E
ngine oil is forced into the turbine and
compressor
n S
 tiffness of mechanical parts
(adjustment, by-pass, wastegate, )
n H
 eavy contamination in the charge-air
cooler
n E
ngine oil collects in the charge-air cooler
n C
 logged exhaust gas cleaning system

n 

Constriction or bend in the oil return pipe

n O
 il level too high in engine
n U
 se of sealing compound instead of
gasket set
n R
 eplace the return pipe but without
changing the engine connection

n 

Damage from
contamination
in compressor

n 

Black smoke
n L
oss of performance
n N
 oise (whistling)
n C
 ontamination in the charge-air cooler

n 

Contamination enters the compressor via

the intake system

n 

Damage from
contamination
at compressor
wheel

n 

Black smoke
n L
oss of performance
n N
 oise (whistling)
n C
 ontamination and damage to the
charge-air cooler

n 

Loose deposits from the crankcase

ventilation
n I
ce forms in the intake system
n F
ragments from previous turbocharger
damage
n L
eak in the intake system
n A
 brasive wear of compressor blades

n 

Cracks in the
turbine casing

n 

Loss of performance at low speeds

n 

Immediate switch off of the hot engine

n O
 verheating through incorrect setting of
the injection system
n I
nappropriate tuning

n 

Stress marks
on compressor
wheel

n 

Blue-smoke
n L
oss of performance
n N
 oise
n H
 eavy contamination in the charge-air
cooler
n C
 logged exhaust gas cleaning system

n 

Bearing damage due to dirty oil

n B
 earing damage due to oil deficiency
n I
ncreased exhaust back pressure
n C
 logged air filter

n 

Turbine wheel:
damage due to
contamination at
gas inlet edges

n 

Blue-smoke
n L
oss of performance
n N
 oises
n H
 eavy contamination in the charge-air cooler
n C
 logged exhaust gas cleaning system
n S
 tiffness of mechanical parts (adjustment,
by-pass, wastegate, ...)
n E
lectronic control unit switches to
emergency programme

n 

Contamination enters the turbine via the

engine
n L
oose parts in the exhaust manifold and
exhaust gas cleaning system

n 

Pay attention to the prescribed oil grade.

n L
et the hot engine run on for at least one minute.
n P
ay attention to the necessary measures during tuning.
n F
lush the oil after turbocharger damage so that no deposits enter the lubricant
circuit.
n Dismantle oil pan and clean carefully.
n R
 eplace the turbocharger after flushing with oil.
n P
ay attention to installation instructions.
n O
 bserve oil change intervals.
n S
 ignificantly shorten the oil change interval if running with biological fuels.
n C
 hange the oil and oil filter as well as the air filter if you replace the turbocharger.

The oil pipe must be renewed when the turbocharger is replaced and laid
correctly.
n P
ay attention to the prescribed oil grade and observe the set oil change
intervals
n T
he charge-air cooler must be replaced if the turbocharger is damaged.
n C
 hange the particulate filter and check the catalytic converter if the turbine
wheel is damaged.
n C
 arefully clean the intake system.
n C
 hange the oil and oil filter as well as the air filter if you replace the turbocharger.
n S
 ignificantly shorten the oil change interval if running with biological fuels.
n P
ay attention to installation instructions.
Use only the matching mounting gasket set.
n E
xchange oil pipes.
n C
 lean the oil return pipe connection to the engine carefully.
n D
 ismantle oil pan and clean carefully.
n C
 arefully clean the charge-air cooler, replacement is better.
n I
f mechanical parts are stiff (VTG, by-pass, wastegate, ) replace the
turbocharger.
n C
 hange the oil and oil filter as well as the air filter if you replace the turbocharger.
n S
 ignificantly shorten the oil change interval if running with biological fuels.

Carefully clean the complete intake system.

n R
 eplace air filter.
n R
 eplace charge-air cooler.
n R
 eplace turbocharger.
n I
n commercial vehicles, dismantle the cylinder head of the air compressor and
clean it carefully.
n R
 ead out error memory and check the mass air flow sensor.
n C
 hange the oil and oil filter as well as the air filter if you replace the turbocharger.

Carefully clean the complete intake system.

n C
 arefully clean or renew the crankcase ventilation.
n R
 eplace turbocharger.
n R
 ead out error memory and check the mass air flow sensor.
n C
 hange the oil and oil filter as well as the air filter if you replace the turbocharger.
n C
 arefully clean or renew the charge-air cooler.
n C
 lean the air intake system.
n C
 heck intake system for leaks.

Replace turbocharger.
n C
 hange the oil and oil filter as well as the air filter if you replace the turbocharger.
n L
et the hot engine run on for at least one minute.
n C
 heck the engine management system.

Check bearing clearance of the turbocharger shaft.

n C
 heck condition of engine oil, flush engine if necessary.
n C
 heck oil pressure.
n C
 hange the oil and oil filter as well as the air filter if you replace the turbocharger.

Endoscopic examination of combustion chambers.

n C
 heck exhaust gas cleaning system for contamination and mechanical damage.
n C
 heck and if necessary replace all turbocharger lines.
n C
 heck and if necessary replace charge-air cooler.
n C
 heck and if necessary replace compensator pipes and manifold.
n R
 eplace turbocharger.