Turbocharger Failure Analysis

Gus Wright

Symptoms of Turbo Failure

1.
2.
3.
4.
5.
6.
7.

Low or no boost (Performance complaints)

Noise
Oil leakage
Poor transient response (i.e Lazy lag)
Blue smoke
Fault codes
Excessive combustion temperature (i.e. Heat
damaged cylinder components, exhaust manifold
and exhaust pipes)
Causes of turbocharger failure varied

Verifying Performance Complaints

Must road test or use dynamometer to
verify low power complaint.
Intake boost pressure which meets
minimum specifications generally means
the turbocharger and engine are
performing satisfactory.

Low Boost = Low-power

Boost pressure gauge

No/low fuel = no boost.

Restricted air flow =
poor combustion and
low-boost

Sources of Noise

Bearings & Leaks

Noise
Some turbochargers will
create unusual noises
during acceleration.
Warble or (Woofing or
barking during
deceleration) is
commonly caused by
surge when the
compressor wheel speed
is unable to correctly
move air due to
aerodynamics of the
housing.

Bearings Coked

Coked bearings caused by hot shut-down.

Causes contact of rotating compressor or turbine wheel with turbo
housings

Bearings

Bearing damage due to hot shut down

Pre-lube Turbo Bearings!

Inspecting Turbo Bearings

Up & Down
radial play.
In & Out Axial
play

Bearing Inspection
One technique for
measuring radial
movement

Axial End-Play Measure

Turbine Shaft Damage

Hot shut-down

Compressor Wheel Damage

Note difference
between damage
caused by hard
and soft objects

Compressor Wheel Damage

Over-speed

Oil leakage
Oil leakage is
not acceptable.
Too much idling,
High crankcase
blow-by
pressure
Worn/damaged
seals

Oil leakage 1
All turbos wisp some
oil.
Crankcase oil is
drawn into
turbochargers of
some closed
crankcase systems.

Intercooler hoses weeping oil

Evaluating Oil Leaks

Turbine Seal Damage

Missing oil seal

Turbine Oil Seal