Guarantee malfunctions

 

 

NEVER continue to operate an engine with a suspect or noisy turbocharger as this could result in a total engine failure.

 

1. Impact Damage

Impact damage caused by foreign material entering the turbine housing or compressor cover is clearly visible on the turbine and compressor wheels. It is important that the air intake and exhaust manifold are carefully checked when fitting a replacement turbocharger.

Never attempt to straighten blades as they will fail later in service.

Never continue to operate turbocharger with damaged blades as the rotor balance be affected and impact service life.

 

2. Dirty Oil

Dirty oil damages the turbocharger with heavy scoring of critical bearing surface. To avoid damage, oil and filters should be of good quality and changed when a new turbocharger is fitted and at the regular intervals according to the vehicle/engine manufactures specification.

Dirty oil damage could result from:

a) Blocked, damaged or poor quality oil filter

b) Dirt introduced during servicing

c) Engine wear or manufacturing debris.

d) Malfunctioning oil filter by-pass valve.

e) Poor quality oil carbonizing in service.

 

3. Oil Delay

Interruption to the oil supply for repetitive short durations (4-5 secs) causes and burnishing to the turbocharger bearing surfaces. This would normally result from failure to prime or pre-crank the engine after:

a) Re-fitting a turbocharger without priming the lube system.

b) Oil and filter change

c) Long periods of non-use

d) Incorrect start up procedure, especially in sub-zero climates

e) Low engine oil pressure due to malfunctioning lube system.

f) Oil contamination - Eg. Glycol or fuel dilution.

g) Operation at excessive engine inclinations.

 

4. Oil Starvation

Severe shortage of oil over prolonged periods ( in excess of 8 to 10 sec) will result in the turbocharger bearing system showing signs of heat discolouration, in addition to polishing and burnishing on critical surfaces

a) Broken or restricted oil feed pipe

b) Oil pump failure

c) Low or no oil in sump

d) Excessive engine operating angles loosing lube system prime.

e) Air leaks into lube system.

 

5. Over Heating

Failure from excessive exhaust temperatures or shutting the engine down without allowing time for the turbocharger to cool down results in carbon build-up.

It is recommended to idle engine for 2 to 3 minutes to cool turbocharger before shutting down.

Turbine and heat soak in to bearing housing results in oil carbonization and corrosion of the bearing system. The main damage occurs to the shaft seal ring and grooves, turbine and bearing and bearing housing oil drain cavity blockage. Severe cases also result in turbine housing inlet flange distortion and cracking. Causes:

1) Blocked air cleaner/excessive intake restriction

2) Hot shutdown damage

3) Poor oil quality carbonizing in service

4) Infrequent oil change intervals causing oil breakdown in service.

5) Air and gas lekas.

6) Faulty fuel injector pimp/injectors

7) Non approved turbine housing installation.