Fault Finder
There are three main reasons for turbo failure:-
Lack of lubricant
Ingestion of foreign objects
Contamination of lubricant
These problems must be addressed before the fitting of a replacement turbo.
All repairs carry a full 12-month warranty as with all new turbochargers.
- Dirty air filter system
- Suction and pressure line distorted or leaking
- Excessive flow resistance in exhaust system/ leakage upstream of turbine
- Fuel system/injection feed system defective or incorrectly adjusted
- Valve guide, piston rings, engine or cylinder liners worn/increased blow by
- Dirty compressor or charge air cooler
- Boost pressure control swing valve/poppet valve does not close
- Foreign body damage to compressor or turbine wheel
- Insufficient oil supply to turbocharger
- Fuel system/injection feed system defective or incorrectly adjusted
- Boost pressure control swing valve/poppet valve seized in closed position
- Boost pressure-sensing pipe split or incorrectly fitted
- Wastegate actuator diaphragm split
- Wastegate actuator calibration incorrect
- Turbocharger bearing damage
- Defective air filter piping/system
- Foreign body from engine damage entering turbine inlet
- Excessive boost pressure
- Dirty air filter system
- Excessive flow resistance in exhaust system/big bore exhaust
- Oil drain pipe clogged
- Crankcase breather clogged/piping restricted
- Sludge in turbocharger centre housing
- Valve guide, piston rings, engine or cylinder liners worn/increased blow by
- Dirty compressor or charge air cooler
- Piston ring sealing defective
- Excessive turbocharger bearing clearances
- Engine oil level too high
- Gasket sealer used on oil drain gasket
- Dirty air filter system
- Induction and intercooler pipes collapsing
- Excessive flow resistance in exhaust system/ leakage upstream of turbine
- Fuel system/injection feed system defective or incorrectly adjusted
- Valve guide, piston rings, engine or cylinder liners worn/increased blow by
- Restricted intercooler or charge air cooler
- Boost pressure control swing valve/poppet valve seized in the open position
- Pipes to actuator and boost control valves incorrectly fitted
- Turbocharger bearing damage
- Foreign body damage on compressor or turbine
- Turbine housing/flap damaged
- Insufficient oil supply to turbocharger
- Engine valve timing incorrect
- Accelerator cable maladjusted
- Insufficient fuel flow/pressure
- Dirty air filter system
- Excessive flow resistance in exhaust system
- Oil drain lines clogged, leaking or distorted
- Crankcase ventilation clogged and restricted
- Coke and sludge in turbocharger centre housing
- Valve guide, piston rings, engine or cylinder liners worn/increased blow by
- Dirty compressor or charge air cooler
- Piston ring sealing defective
- Turbocharger bearing damage
- Engine oil level high
- Excessive oil pressure
- High mileage engine
- Excessive flow resistance in exhaust system/big bore exhaust
- Oil drain lines clogged, leaking or distorted
- Crankcase ventilation clogged and restricted
- Coke and sludge in turbocharger centre housing
- Valve guide, piston rings, engine or cylinder liners worn/increased blow by
- Dirty compressor or charge air cooler
- Piston ring sealing defective
- Turbocharger bearing damage
- Engine oil level high
- Excessive oil pressure
- High mileage engine
- Inlet manifold gasket leaking or incorrectly fitted
- Intercooler piping split/intercooler damaged
- Exhaust manifold gasket leaking
- Exhaust system corroded
- Turbine housing mounting flange gasket leaking
- Exhaust gas leakage between turbine outlet and exhaust pipe
- EGR valve not seating correctly
- EGR valve piping broken
- Turbocharger bearings worn
- Restricted air filter
- Imbalanced turbocharger rotating assembly
- Damage to compressor wheel inducer blades
- Damage to turbine wheel assembly
Compressor Wheel – ‘Mouse & Nut’ Damage
Compressor Wheel – ‘Mouse & Nut’ Damage You couldn’t make this one up. One of our customers had parked their car up for winter and during this time, some mice had taken refuge in the airbox. When the customer came to use the car again in the spring and started up the engine, some nuts
Compressor Cover Damage – Scoring
Compressor Cover Damage – Scoring This image illustrates scoring out of the compressor cover profile, and occurs when excessive wear and movement in either the thrust bearing or journal bearing (or both) causes excessive movement in the rotor. In turn, this causes the compressor wheel to rub against the compressor cover, scoring out the profile.
Compressor Cover damage – Corrosion
Compressor Cover damage – Corrosion In the image, you can see corrosion damage to the seal area and inlet of the compressor cover. This type of damage is extremely common with Porsche units as, with the turbos sited so low down on the vehicle, they catch all the road debris that gets flung up from
Wastegate Actuator damage
Wastegate Actuator damage Faulty or damaged actuators are the cause of many of the turbo problems we see at AET, but they can be easy to overlook. The wastegate actuator acts as a pressure relief valve, which ultimately controls the boost output of a turbocharger. It works by holding the wastegate shut until the required
Compressor wheel damage – Overspeeding
Compressor wheel damage – Overspeeding In these images, you can see that the back of the compressor wheel has become rippled and pitted, which are early signs of damage caused by overspeeding. Overspeeding damage like this occurs when a vehicle’s engine causes the turbo to spin faster than it is designed to. This excessive speed
Compressor wheel damage – serious overspeeding
Compressor wheel damage – serious overspeeding Here’s a more serious example of overspeeding damage – in this image, the compressor wheel has actually exploded into pieces due to extreme overspeeding! Damage like this can be caused when a turbo spins so fast that it starts to bend the turbine shaft at the thrust shoulder. In
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