Fix turbo failure? (Professionals recommend)

  • Sometimes the only way to fix this problem is by taking apart the induction system and post-turbo charge pipes. While there is bound to be some residue left in the system, if the oil is pooling, you need to replace the seals. Wearing of the Bearings

Can a faulty turbo be repaired?

Make sure your car mechanic does a thorough check-up of the turbocharger before suggesting you replace it. More often than not, the turbocharger can be revived by a skilled mechanic. Only when the blades of the turbocharger have been heavily damaged, does the turbocharger go out of repair.

What happens if a turbo fails?

Be aware that when your turbo fails the pieces will drop down into the intercooler and the oil seals will fail. Unfortunately the engine can actually run on this oil and can run away at maximum RPM until all the oil is used up, at which point the engine will seize.

How do you stop a turbo from failing?

4 tips to prevent turbo problems

  1. Regular maintenance. It is important that the vehicle is serviced on time and on a regular basis.
  2. Timely oil changes. The engine oil must be changed correctly and on time.
  3. Use of correct and good quality engine oil. The engine oil must of course meet the prescribed quality.
  4. Gentle startup.

Can you drive with a blown turbo?

Yes, you’ll still be able to drive your car if your turbocharger fails; however, engine failure won’t be far behind, so only drive on if you have to. As soon as you spot any of the turbo failure symptoms outlined above, you should get your turbo checked as soon as possible by a qualified technician.

Can you drive with a bad turbo?

You can, but you’ll have to come up with some way to re-plumb everything. I had a 2.3L EFI turbo in a Mustang that blew up on me. It was pouring oil down the exhaust pipe so I couldn’t just drive it with a blown turbo.

How do I know if my turbo is going bad?

The most common signals that you may have a blown turbo are:

  1. The car has noticeable power loss.
  2. The acceleration of the car seems slow and noisy.
  3. The car doesn’t easily maintain high speeds.
  4. There is smoke coming from the exhaust.
  5. There is an engine fault light on the dashboard.

At what RPM does turbo kick in?

The turbine in the turbocharger spins at speeds of up to 150,000 revolutions per minute, which is 30 times faster than most car engines can go. The turbine’s temperatures are very high since it is hooked up to the exhaust.

What causes turbo failure?

Most failures are caused by the three ‘turbo killers’ of oil starvation, oil contamination and foreign object damage. More than 90% of turbocharger failures are caused oil related either by oil starvation or oil contamination. Blocked or leaking pipes or lack of priming on fitting usually causes oil starvation.

How much does it cost to fix a turbo?

Turbocharger Labor and Part Costs The price of a turbocharger typically starts from $400 and goes up depending on the make and model of your car. For smaller cars such as an Audi A4, or a Subaru Impreza you can expect to pay less for a replacement turbocharger.

Can a diesel car run without a turbo?

So a diesel engine without a turbo doesn’t make much power and if you try to adjust the fuel or timing to add power, you can only go so far before the lack of air becomes a problem. This is why all modern diesels use turbochargers.

Can you drive a turbo car without a turbo?

Yes. The engine will still work and you will be able to drive the vehicle but it will be slower than the equivalent vehicle that doesn’t have a turbo. It won’t do any damage to drive a turbo car with no boost. Many cars have a ruptured boost pipe or a burst intercooler which means they have No boost.

Can water damage a turbo?

Unfortunately, yes. The turbo is spinning at least 10,000 rpm even at idle. If it hits something like a paper towel or a signifigant amount of water, the turbo wheel usually touches the housing or the bearing gets ground up. Even if the damage isn’t immediate, it builds up since the turbo has to be balanced.

What oil is best for turbo cars?

Mobil 1 oils are setting the standard for turbocharged engine performance and protection.

What Causes Turbo Failure & Common Turbo Failure Symptoms

At 9:10 a.m. on July 25, 2019, Turbocharger, commonly referred to as a turbo, is an extra mechanism utilized by automobile manufacturers to increase the power of their engines. In order to give the same amount of power in smaller vehicles as is often seen in bigger vehicles, turbochargers are frequently employed. Almost all automobile manufacturers now offer a turbocharged version of their vehicle in their lineup. In other words, they will be able to deliver smaller engines that provide the same amount of power while simultaneously improving fuel economy.

How Does A Turbo Work?

Fuel and air must be combined in order for an automobile engine to generate the power necessary to move the wheels. Turbochargers increase the amount of air in the mixture by spinning an air pump powered by the exhaust (or compressor). The air pump then forces additional air into the engine’s cylinders, allowing the engine to burn more gasoline per second and create more power than a normally aspirated engine would be capable of. Due to the fact that turbos work at extremely high speeds (up to 250,000rpm), they must function at extremely high pressures and temperatures.

Turbo Failure Symptoms

There are a lot of indicators that your turbocharger has failed that you should be aware of:

POWER LOSS

The failure of your turbo may be indicated by the fact that your automobile isn’t accelerating as quickly as it once did or is reacting more slowly to your input than it once did. The same is true for a turbocharged vehicle that struggles to maintain high speeds or that is unable to attain speeds it was previously capable of achieving.

WHINING ENGINE

Another surprising benefit of a turbocharger is that it actually makes the engine quieter by muffleing the sound of air intake, which helps to reduce noise pollution. But if you start hearing a loud, whining noise that sounds similar to a dentist’s drill or police siren, this might be an indication of turbo failure. Fortunately, this is rare. As the severity of the defect increases, the level of noise will increase. Whenever you hear a whine coming from your engine, you should take your vehicle to a competent technician for an inspection.

EXHAUST SMOKE

When oil spills into the exhaust system, it burns off and emits a characteristic blue/grey smoke as it escapes via the exhaust pipe. This might be caused by a crack in the turbo housing or by broken internal seals in the turbocharger unit. If the turbocharger is to blame for this symptom, you’ll be more likely to notice these discolored vapors when the engine rpm climb quickly after starting the engine.

CHECK ENGINE LIGHT

Most current automobiles are equipped with computer diagnostics that can detect turbo failures, and the check engine light will illuminate on the dashboard to alert the driver of the problem.

The check engine light, on the other hand, does not always imply turbo failure; you will need to consult with a competent technician to determine the specific nature of the engine problem.

What Causes Turbo Failure?

Turbochargers have a high level of dependability. Only a small percentage of warranty checks uncover a problem with the turbo itself; instead, blown turbos are typically the consequence of issues with engine lubrication or the entrance of foreign items.

OIL/LUBRICATION

Engine oil is, in a sense, the lifeblood of your automobile. Its primary function is to lubricate and protect critical moving components from corrosion, as well as to keep them cool while in operation. When it comes to the turbocharger, it requires a continuous supply of clean, high-quality oil. An inadequate supply of oil (oil starvation), an inappropriate grade of oil, or low quality oil may result in a buildup of pollutants in the engine’s internal combustion system (oil contamination). This has the potential to inflict abrasive damage to the turbocharger’s inside.

DAMAGED SEALS

It is possible for oil to seep into an exhaust system if the seals between the compressor and the engine get old or fractured. As a result, the turbo is forced to work harder in order to raise air pressure in the engine. Over-speeding is another term used to describe this issue. In the end, it will lower the efficiency of the turbo and the amount of boost it can deliver.

FOREIGN OBJECTS/DEPOSITS

An engine turbocharger is composed mostly of two primary components: the compressor located at the front and the turbine located at the rear of the engine. Foreign items such as dust particles, dirt, leaves, and tiny stones can occasionally make their way into the turbocharger, either through the compressor intake or the turbine inlet. When a foreign item enters the compressor housing, it is most typically the result of a clogged air filter. If, on the other hand, the foreign item causes harm to the turbine, the problem is almost often caused by the engine itself, as opposed to the other way around.

Your air filter should be maintained and replaced on a regular basis in order to avoid this from happening.

WEARTEAR

Turbos are intended to last for the life of the vehicle (or around 150,000 miles); nevertheless, depending on how hard you drive the car and the original build quality of the turbo, it is likely that they will wear down over time and require replacement.

Can I Drive With A Blown Turbo?

It is true that you will be able to drive your car if your turbocharger fails; but, engine failure will not be long behind, so only continue driving if you really have to. As soon as you notice any of the turbo failure symptoms listed above, you should get your turbo examined by a trained technician as soon as possible. The longer you put off dealing with the problem, the worse (and more expensive) it will get. At Dowleys Garage, we can perform a diagnostic check to determine the source of the problem and provide recommendations for any necessary repairs.

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to 12:00 p.m. on Saturdays. If you have any questions, you may contact us by phone at 01993 842345, by email at [email protected], or by filling out our online contact form. Category: ‘Expert Advice’ is a tag that refers to the category ‘Expert Advice.’ Return to the list of all blogs

Worried about a blown turbo? Know all about Turbo Repair

The turbocharger is intended to last as long as your automobile. However, the turbo can become damaged with time, which is why you should be well-versed in the subject of Minnesota Turbo Repair. During this blog post, we’ll go over the telltale indicators of a blown turbo, the most prevalent causes of turbo failure, and what to do if your turbocharger fails. As well as Turbocharger Replacement, Garret Turbochargers, and why Diesel Components, Inc. should be your first choice for everything relating to Turbo Repair or Replacement, we’ll cover the following topics:

See also:  Best mechanics tools? (Correct answer)

What are the signs of a blown turbo?

  • The car’s age and mileage are important considerations. There is not enough engine oil in the system. The wrong type of oil was used
  • Seals that have been damaged (this permits oil to enter the exhaust system)

If your turbo fails for any reason, many signs can be present. The tell-tale signs of the most common turbo problems can be identified if you closely monitor the way your car performs, which is something you should do. Therefore, you can confirm the possible turbo issues, with the need for our services to run a diagnostic test to pinpoint the root of the problem. When you visit us, we can also talk to you about turbo rebuilding.

The most common signs of a blown turbo are:

  • Your vehicle is experiencing a notable decrease of power
  • Your car’s acceleration appears to be sluggish and loud
  • Nevertheless, this is not the case. Your vehicle has difficulty maintaining high speeds
  • There’s a cloud of smoke billowing out of the exhaust
  • On the dashboard, there is an engine problem light illuminated.

Common reasons why your turbo has failed:

There are a variety of reasons why turbochargers malfunction. The following are the most often encountered:

Carbon/particle deposits

When you don’t replace your oil on a regular basis, carbon deposits begin to accumulate. Make certain that the company replaces your oil every time you bring your vehicle in for repair. The addition of a turbocharger provides several advantages to the general health of your car. Even the presence of very modest quantities of pollutants in it can result in costly and troublesome mechanical problems.

Weartear

Turbos are intended and manufactured to survive for many years, but they will ultimately fail, just like the rest of your car’s components. If you don’t use your turbo much, you may anticipate it to last roughly 150,000 miles or even longer if you maintain it properly.

Cracked/damaged seals

Turbochargers inject extra air into your car’s cylinders, increasing the amount of pressure in the engine. If the essential pressure in your turbo is reduced as a result of cracks in the turbo, your turbo will have to work harder to give the appropriate turbo boost, finally leading it to fail.

What should I do if my turbocharger fails?

The most important stage is to determine the root cause of the failure in order to prevent the same thing from happening again. Turbo failures can occur for a variety of reasons, each with its own set of characteristics. If something acted on the turbocharger and caused it to fail, you must correct the situation. If you bring your failed turbo to us, we can examine it and discuss the findings with you in order to steer you in the proper way and get you back up and running as soon as possible.

Below are some things that our expert team at Diesel Components, Inc. will inspect if your turbocharger fails

This list is not exhaustive because some engines have additional components that must be checked as well. Continue reading to learn about some of the things we’ll be doing when fixing your turbo:

  1. We will take some time to evaluate the air intake and exhaust systems to verify that they are in good working order and clear of pollutants before continuing. The exhaust or intake system of your vehicle might become clogged with components of your failed turbo if your turbo fails catastrophically. They may return after the new turbo is installed, resulting in damage to the new turbo
  2. We will change the oil and filters to prevent this from happening. This would be done after removing the sump to ensure that all of the material that was causing the turbocharger failure has been removed. After that, we’ll remove the oil feed pipe and fittings and examine them for any contamination. You can also request that we change the air filter if you so want. Our technicians will check the intercooler since there may still be small amounts of oil or pieces from the original failed turbo lurking within it. When a catalytic converter or diesel particulate filter (DPF) is present in the exhaust system, we shall clean or replace them to guarantee proper performance. We will inspect the intake pipes for fractures and corrosion. Finally, we will look for any signs of exhaust leakage. Is it possible to drive with a blown turbo?

The longer you keep your automobile on the road with a damaged turbo, the more harm it will do to the engine. This will also increase the expense of your turbocharger repair above and above what it should be. Despite the fact that you may still drive with a blown turbo, it is far advisable to stop driving and instead bring your vehicle to us so that we can repair or replace the turbo.

The longer a blown turbo is allowed to go without being repaired, the more harm it will do to the car’s engine and transmission.

Turbo replacement service near Minneapolis

Sometimes, at Diesel Components, Inc., we might recommend that you replace a blown turbo instead of attempting to fix it. We provide our clients the assurance that the new turbo is protected by the manufacturer’s warranty since we use only original equipment manufacturers’ parts. But which turbocharger should you put your faith in? In this article, we’ll explain why Garret Turbochargers are the finest on the market:

Why Choose Garrett Turbochargers Over Some “No Name” Aftermarket Unit?

Replacement with the same model of turbocharger, if your vehicle’s turbocharger was originally produced by Garrett when it was constructed, assures that you get the performance, efficiency, and dependability you expect.

Durability

Garrett is no stranger to the automotive sector, having supplied millions of turbochargers to nearly every engine builder in existence throughout the course of its history. Garret Turbochargers are made with the same high-quality materials and with the same level of assembly precision that the OEM demands. As a result of its high-quality components, your application will have the longest possible operational life.

Cost

Our selling price will save you money over the cost of the same unit from your dealership, and it is quite comparable with ‘no-name’ generic units of poorer quality that are available elsewhere.

Warranty

All Garrett turbochargers are backed by a 12-month warranty that covers the whole country. It provides you with piece of mind since you now know that your purchase is backed by a firm you can rely on.

Call Diesel Components Inc. for Turbo Repair Now

If you see any of the warning symptoms listed above, it is critical that you take action. If you are still unsure, you may bring your vehicle to us for a professional evaluation. Our skilled technicians at Diesel Components, Inc. can readily observe and inspect numerous modern automotive turbochargers, also known as turbochargers, which are used to increase the engine’s output power. The regular servicing and maintenance provided by Diesel Components, Inc., Burnsville’s biggest service facility, will guarantee that your turbocharger continues to operate at peak performance levels.

can also provide you with the best-in-class Turbo Repairs for your diesel engines or fleet requirements, depending on your needs.

Turbocharger troubleshooting

Sometime a truck will come into the shop with its owner saying that there is a problem with the turbocharger. While this may be true, it is also conceivable that the turbo was a victim of circumstance, and that there are alternate explanations for why the turbo has failed. For more than a decade, says John Ferry, executive vice president of TurboSolutions, turbochargers have been a popular topic in repair shops. He believes the industry is still in the process of becoming more knowledgeable about turbochargers.

  • Simple turbos were replaced with more complicated variable geometry turbos (VGT), which cost six times as much as their predecessors.
  • Service providers that are fast to switch out a turbocharger without thoroughly evaluating the rest of the system stand a strong possibility of seeing a dissatisfied client in a few months who is complaining about the same problem they had initially.
  • As a result, when something goes wrong, it usually goes wrong quickly.
  • In order to fully comprehend a turbo failure, it is necessary to identify and eliminate its fundamental cause.
  • If an engine has an electrical turbocharger, the technicians should check the electrical connections for damage as well as all pipework and clamps as well as oil and water lines.
  • One of the most prevalent issues is that turbochargers are returned even if there is nothing wrong with them.
  • ‘It’s referred to as misdiagnosis,’ Ferry explains.

They take their chances and ship it back to the manufacturer for warranty coverage.

A handful of warning indicators (see chart from Turbo Solutions) are most frequently seen by technicians while diagnosing suspected turbocharger faults, according to industry experts.

BorgWarner is the source of this information.

‘The fact is that it may not be the turbocharger at all; it may be a shortage of air and as assimple as an air cleaner, but they will almost certainly blame the turbocharger,’ Golema explains.

‘Excessive exhaust limitation might result in a loss of power,’ he continues.

In the case of an out-of-balance turbo, it will generate a different sound; if the turbo has been damaged and a blade has been chipped, the pitch that the turbo is designed to produce will be altered, explains Temple.

He recommends that you check for an obstruction in the turbocharger’s oil supply.

‘Noticing unusual pitch is one technique to identify a problem, but you must first discover the unusual pitch.

Additionally, the color and position of the smoke can provide indications as to what could be creating troubles with the turbocharger or another element of the truck.

There are two possible reasons for this: either the fuel condition is excessively rich or the turbocharger is ineffective.

‘You have to figure out why it isn’t getting any air flow.

If the turbo is operational, but it is unable to provide air to the turbo due to a blocked air filter, is this a cause for concern?’ Temple expresses himself.

Other possible causes of blue smoke include a blocked, leaky, or distorted crankcase ventilation system, coke and sludge in the turbocharger center housing, and a filthy air filter system, among other things.

Experts believe that turbochargers are particularly vulnerable to soot and foreign object impact damage (FOID).

Back pressure is formed and soot accumulates inside the turbocharger if the diesel particulate filter — and the aftertreatment system as a whole — is not properly functioning or maintained, for example.

‘If you have a badvalve that becomes completely carbonized, little particles of carbon can break off and go into the turbocharger,’ says the author.

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‘Aftertreatment is meant to function in conjunction with the turbo,’ Temple continues.

If anything, it puts additional strain on the turbo, yet it is necessary for the system to function properly.’ The turbocharger is being inspected The interior of the turbocharger can disclose damage as well as information as to what could be causing it because turbochargers are meant to last the whole life of the engine.

  1. The operator will be informed if there is a problem with the actuator by a code shown on the instrument panel, however this may not be the case.
  2. Taking the actuator out of the equation allows technicians to inspect the VGTlever, which travels up and down.
  3. According to him, if the lever can be moved freely, the turbo is in good working order.
  4. He also recommends that the rotor system be moved manually in both the axial and radial directions.
  5. Because of overspeeding or a large amount of contaminated oil passing through the turbo, the bearings will begin to wear down, and the customary clearances for end (or axial)play and radial play will allow the turbo to operate outside of its specified limits, according to Temple Engineering.
  6. BorgWarner Checking the turbocharger and turbine for debris, grease, or sludge in the housing might cause the turbocharger to get clogged.
  7. TurbochargerTLC specialists agree that lubrication, filters, and periodic maintenance are the most critical aspects of keeping a turbocharger healthy and working as it should.
  8. ‘If that supply line is not delivering enough oil to the turbo, you run the danger of the turbo burning up in three seconds,’ he continues.
  9. It is possible that components in the engine aftertreatment system might shorten the turbo’s life if you do not follow these instructions.
  10. ‘Use the factory-recommendedOEM oil that is approved for your vehicle.

He advises to ‘do those two things and you’ll be relatively safe when it comes to the engine and turbocharger.’ Ventress also points out that the turbocharger is affected by crankcase ventilation, thus maintaining the crankcase ventilation system — filters and pipes — clean and clear can substantially improve the turbocharger’s capacity to seal oil in the turbo bearing housing, according to the manufacturer.

High crankcase pressure as a result of inadequate ventilation is a typical cause of oil leaks from the turbocharger.

In the words of Headds, ‘Maintaining the engine properly will protect the turbocharger, and it is extremely crucial that end users adhere to the engine OEMservice intervals and utilize authentic components wherever feasible.’

Fix turbo failure

This generation of turbochargers has been on the market for quite some time, and some of them are beginning to fail. The breakdown of a turbocharger might result in extra and costly engine damage. That is why you should address turbo-related issues as soon as possible (see turbo failure symptoms below). However, if your turbo fails, here’s what you should do.

Also interesting: Fix turbo failure? (Professionals recommend)

Check the terms of your powertrain warranty or extended warranty

Turbo replacement is a pricey endeavor, so check your powertrain or extended warranty to see whether it is covered under your coverage. Assuming you’ve adhered to the automobile manufacturer’s suggested maintenance plan, if you purchased an extended warranty that covers everything bumper to bumper, the odds are good that it will be covered (see Turbo maintenance tips below). If your warranty just covers the powertrain, the question is whether or not the turbocharger is considered part of the powertrain.

Take a look at your warranty and make a beeline for the area labeled exclusions.

If it is covered, the warranty should cover the cost of the replacement turbo as well as any engine damage that may have resulted (read Tubo maintenance section).

What if your turbo isn’t covered by a powertrain warranty or extended warranty?

It is, without a doubt, necessary to replace it. But first, figure out why it didn’t work. Turbos may spin at speeds of up to 200,000 rpm and require a sufficient amount of cooling and lubrication. It is possible that the new turbo will fail if your car has a cooling-related problem and you do not address it immediately. The same is true for lubrication; it must be addressed immediately. After then, look through pattern failure databases and technical service bulletins for further information.

Numerous occasions, both the automaker and independent repair shops are able to identify circumstances that lead to the failure of a component.

If the manufacturer has introduced new components or installation/cleaning techniques since the automobile was manufactured, your mechanic should consult the manufacturer’s technical service bulletins.

A rebuilt turbo may be purchased for less than half the price of a new turbo from a dealer.

Causes of turbo failure

The indications of turbo failure described below can be caused by a variety of other engine problems, so perform a thorough inspection before concluding that the turbo is at fault. Performance that is sluggish: Once you reach 1,000-1,500 RPM, the turbocharger should kick in and deliver a perceptible boost in power. This is referred to as turbo tip-in. Take a look at the turbo if you aren’t seeing any more power. The Check Engine light is illuminated. The moment the turbocharger engages, the engine’s performance changes.

Whining sounds: A failed turbo can make a noise similar to that of a dentist’s drill or a police siren.

It is possible that the compressor wheel or bearing will fail if you let it run and the shards would cause engine damage.

Because of a failure of the seal between your cooling line and bearing, your turbocharger may pump coolant into your engine, resulting in white/brownish clouds of smoke coming out of your exhaust. The failure of an oil seal might result in blue or grey exhaust smoke.

Turbo maintenance

Turbos operate at high speeds and require a large amount of clean oil and coolant to protect the bearings from overheating. Turbocharged vehicles demand more frequent oil changes than non-turbocharged vehicles. In the event that you haven’t adhered to the expedited oil change schedule, the depleted oil might result in premature turbo failure. The same may be said about coolant. Coolant that has been exhausted promotes electrolysis and causes corrosion. This corrosion can cause coolant flow to be restricted, leading the turbo to run hot and break prematurely.

Passing through the air filter can cause damage to the compressor wheel, resulting in a reduction in boost and an imbalance between the impeller and the turbine.

The intercooler is little more than a radiator-like device that can become clogged with leaves and rat droppings over time.

While inspecting the intercooler, be sure to examine the quality of all of the hoses and seals that link it to the rest of the vehicle.

Turbocharger diagnosis and maintenance

Turbochargers operate at high speeds and require a large amount of clean oil and coolant to maintain the bearings operating at optimum temperatures. Turbocharged vehicles require more frequent oil changes than non-turbocharged vehicles do. In the event that you haven’t adhered to the expedited oil change schedule, the depleted oil might lead to premature turbo failure and engine failure. With regard to coolant, the same applies. It is electrolysis and corrosion that is accelerated by the usage of used coolant.

  1. It is vital to clean your air filter, especially if you travel in dusty or sandy conditions, because the turbo takes its air from the air filter box.
  2. An intercooler is required because the air is heated during turbocharger operation.
  3. For maximum boost cooling, the intercooler must be thoroughly inspected and cleaned.
  4. Rick Muscoplat was born in the year 2016.

Lacks power or poor acceleration

When the majority of turbocharged vehicle owners see that their vehicle lacks power when accelerating and/or does not create typical boost pressure, they realize that something is wrong with their vehicle. A check engine light with OBDII codes such as PO299 (Turbo/Supercharger Underboost Condition) or PO234 (Turbo/Supercharger Overboost Condition) might also indicate poor engine performance (Overboost Condition). There are two main reasons of the error code aP0299: a defective wastegate and a bad boost sensor.

  • A faulty boost sensor might cause the ECU to set the code if it reports boost pressure that is either too low or too high.
  • One of the primary requirements for the occurrence of the code is when boost pressure surpasses a certain threshold for a period of more than 2 seconds.
  • Detection of an over-boost circumstance allows the ECU to enter ‘limp-in mode,’ which limits the engine’s rotational speed.
  • Identifying the fundamental cause of a turbo-related problem is essential for avoiding costly return repairs and keeping your clients satisfied.

Turbo/engine maintenance

There was an unusually high number of warranty claims for faulty turbochargers when Garrett AiResearch Industrial Division (now Garrett Motion Inc.) began mass-producing turbochargers for the automobile industry in the mid-1980s. Turbines were previously thought to be an extremely dependable and low-maintenance device, capable of operating for more than 300,000 miles in diesel engine applications without experiencing any difficulties until today. What had changed, exactly? There was a clear solution to this question – the maintenance habits of individual car owners were substantially different from the maintenance habits of fleet owners of heavy-duty trucks.

Engine maintenance on engines that may cost as much as $40,000 is not cost-effective, and the maintenance plans for these fleets of vehicles were tight in that they were completed on time and with high-quality parts (filters) and lubricants, which was not the case in this case.

Turbocharger lubrication

There was an abnormally large number of warranty claims for faulty turbochargers when Garrett AiResearch Industrial Division (now Garrett Motion Inc.) began mass-producing turbochargers for the car industry in the mid-1980s. Turbines were previously thought to be an extremely dependable and low-maintenance device, capable of operating for more than 300,000 miles in diesel engine applications without experiencing any difficulties before this development occurred. And what was different this time?

Before the 1980s, turbochargers were almost entirely used in the diesel truck and heavy-duty off-road vehicle sectors, with just a small amount of manufacturing going to other applications.

Unlike in other industries, such as the automotive industry, where the majority of vehicle and light truck owners approach maintenance with the attitude of ‘I’ll get around to it when I have the time.’ In other words, ‘until there is a problem with my automobile, I never take it to the shop.’ However, a turbocharger will not last as long as an engine because of this lack of maintenance.

Intake and exhaust plumbing

Low turbo boost and poor engine performance might be caused by air leaks in the compressor outlet piping, intercooler, throttle body, or intake manifold, among other places. If you hear whistling noises coming from under the hood during a test drive, it’s most likely due to a leak in the compressor/intercooler or the exhaust/turbine system. Overspeeding is a situation induced by leaks between the compressor and the intake manifold in which the turbo is forced to work harder (spin at rates greater than its design limits) in order to overcome the leak and maintain engine speed.

  1. It is extremely dangerous to spin a turbocharger beyond its intended limitations since it can cause catastrophic damage to the compressor wheel and other components.
  2. Dirt (and particularly sand) may erode the edges of the blades on the compressor wheel, resulting in premature failure.
  3. A saw-toothed surface or a rounding off (even slightly) of the edges indicates that unclean air has entered the compressor housing.
  4. It is possible that leaks between the exhaust manifold and the turbine intake will prevent sufficient thermal energy from entering the turbine, resulting in reduced compressor performance.
  5. The turbo boost produced by a clogged diesel particulate filter (DPF) can be reduced in diesel applications as well.
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Turbocharger quick inspection

If a mechanic is confronted with a low boost level or an engine that lacks power during accelerating circumstances, they are in a difficult position. Engine performance is influenced by turbo performance, while bad engine performance is influenced by turbo performance. In this ‘chicken-before-the-egg’ scenario, there is an approximately 80% likelihood that the turbocharger is not the source of the problem. A turbocharger-equipped engine is liable for any and all of the problems that can (and frequently do) arise in engines that do not employ a turbocharger.

  1. If the turbocharger is only producing a little amount of boost, a fast inspection of the turbo bearings and wheel-to-housing clearances may be performed with your fingertips.
  2. The compressor wheel should be able to rotate freely without becoming stuck.
  3. The flat edges on the compressor blades where they have been scraped against the housing will be seen on a visual inspection in this state.
  4. If a dial indicator is provided, it is possible to do a little more precise bearing clearance inspection.
  5. It is recommended that shaft endplay (in-and-out movement) be within the range of 0.002′ to 0.004′ for both up-and-down movement and endplay (in-and-out movement).
  6. As soon as you identify that a vehicle’s turbocharger has to be replaced, you should investigate the underlying cause of the failure and provide customers with recommendations on driving habits and vehicle maintenance.

This will help to avoid repeating the procedure in the future. Check out the sidebars on Turbo Replacement and Using a Turbocharged Vehicle for further information.

The top reasons for turbo failures

Because turbochargers are essentially dependable, when a client informs you that ‘the turbo has packed up,’ the most likely reason of the failure will be found somewhere in the engine, not in the turbo. The failure of the turbo can be caused by any of the systems that interact with it. Oil supply is the most significant turbo-killer, but there are other factors to consider. The creation of a vacuum can be caused by restricted or blocked air intakes, while the generation of excessive backpressure might be caused by restricted or blocked DPF or Cat filters.

  • Another reason for turbo failure is the ingestion of foreign objects, which can cause damage to the turbo compressor blades.
  • The corporation then creates important instructions, which are made available for free on its website by the government.
  • It is the PSA 1.6 HDiengine crucial instruction that has received the most attention and downloads.
  • EGRA IS STUCK IN EGRA The EGR valve in the exhaust system of theVauxhall Astra, Corsa, Combo, andMeriva 1.7D is a primary source of the problem.
  • BTN Turbo recommends that you remove the exhaust manifold and inspect it for excessive carbon/soot buildup, as well as clean or replace the EGR valve if required, in order to avoid this happening again.
  • It is possible for the engine breather system of some BMW(and Land Rover) diesel engines to get clogged over time, resulting in restricted flow and increased sump pressure.
  • The consumer observes blue engine smoke for the first time.

Although the buyer may believe that there is an issue with the turbo, in reality, the engine need a new breathing filter.

‘This is one of those strange problems; it can manifest itself once a new turbo is installed, but it may not have been noticeable previously.’ DAMAGE CAUSED BY DEBRISA little thing, such as a nut or a washer, can cause severe damage to the turbocharger vanes in a short period of time.

It may happen with practically any turbocharger, although some vehicles appear to be more susceptible to it than others.

Check the interior of the pipes for any debris or filth and clean or replace it if necessary.

PROBLEMS WITH OIL – THE MOST DEVASTRANT TURBO KILLERS The last BTN critical instruction we’ll cover in this post is a combination of two of the most common turbo-killers: oil hunger and oil pollution, respectively.

Over time, this might get clogged, resulting in reduced oil flow to the turbocharger.

When changing the turbo on this application, BTN suggests that you remove and clean the sump, as well as replace the oil strainer and feed pipe, to ensure proper operation.

Checking the oil supply is crucial to avoiding a repetition of the turbo failure, even if the car you are working on does not fall under one of BTN’s key directives.

It maintains a stock of 18,000 turbos from all of the major manufacturers, which are available for next-day delivery to your factor.

The BTN Turbo website has a variety of information that will assist you in diagnosing turbo issues and reducing the likelihood of them repeating in the future. WEB SITE: WWW.BTNTURBO.COM WILL PROVIDE YOU WITH MORE TECHNICAL HINTS AND ADVICE

Turbocharger Troubleshooting 101

As the director of product support for Hartzell Engine Technologies (HET), a manufacturer of turbochargers for certified aircraft piston engines, I receive a great deal of inquiries from aircraft owners and mechanics about these complex equipment. Here are some answers. As a result of this, it becomes evident that the problem, or at the very least its genesis, was due to a lack of knowledge on behalf of either the pilot or the technician about the operation of a turbocharger system. So, let’s start with a brief overview of turbochargers, as follows: The turbocharger of today is only one component of a complex system.

While the turbo itself appears to be a straightforward mechanism, it is actually a very precise component that can function at speeds exceeding 100,000 rpm and temperatures surpassing 1,650 degrees Fahrenheit.

Most problems begin as a failure to communicate

We have observed that most of the returns we receive from the field are not due to difficulties with the turbocharger itself, but rather due to problems with the system’s installation, inadequate pre-lubrication, or other operational concerns, according to our experience. It is common for mechanics to be tasked with examining and diagnosing operational issues, which may include an inability for the aircraft to reach altitude, pressurization problems, an inability for the system to reach its maximum-rated manifold pressure, a surging or dropping off of manifold pressure when climbing or descending, and/or oil leaks from the compressor or turbine side of the turbocharger.

  1. Pilots of turbocharged aircraft must pay special attention to their aircraft’s engine and exhaust system in order to prevent many of these problems.
  2. In many circumstances, the system will alert the pilot or technician to a potential problem before it becomes a major problem in the air.
  3. It is important to note any of these signs since they indicate that it is time to investigate the system’s overall health.
  4. Because the turbocharger and the engine share an oil system, specialists should recommend that owners replace the oil every 25 to 35 hours, depending on the driving conditions.
  5. In addition, the mechanic should take advantage of the chance to perform a comprehensive check of the complete engine and turbocharger system when performing the oil change.

Make sure to visually examine all of the clamps, hoses, ducts, and other associated components of the intake and exhaust systems as well.

Before all else fails, remember the following…

Heat and/or a lack of lubrication are the most prevalent causes of turbocharger failure in the vast majority of cases. Therefore, mechanics must be just as vigilant with engine power control during ground operations as pilots are during flight – and in some cases, they must go above and beyond this. The most typical mistake mechanics make following a ground run is to fail to properly shut down the engine afterward. The needed static run-ups following an inspection or repair allow the turbo to reach its maximum performance.

  1. When you turn off the engine, the oil supply to the crucial turbo components is cut off, which can cause serious damage to the engine.
  2. You must adhere to the aircraft’s procedures and give the turbo time to spool and cool down before shutting off the aircraft.
  3. When the engine is turned off, the flow of air to the turbocharger is cut off at that point.
  4. When coking occurs, it is possible for the bearings to be damaged, causing the bearings to “orbit” rather than “spin.” This will eventually enable contact between the wheel and the housing, resulting in premature wear and failure of the wheel and housing.

Time for a change?

After you’ve determined that the turbocharger is in need of repair, what happens next? In the first instance, visual check of the turbine and compressor wheels should be performed. Pay attention to any nicks, dents, rust, or other signs of wear and tear. There is no way to fix any of these issues at this time. Verify that there is no contact between the wheels and their respective housings following this step. In order to determine how much sludge is there, insert your finger into the oil output port.

Carry out a radial and axial bearing clearance check at this point.

In certain cases, excessive clearance might indicate excessive bearing wear, while in others, tight clearances can indicate excessive coking accumulation.

As a result, field repairs are not something that should be attempted by a conventional repair shop.

A question I am asked a lot is ‘what is your favorite movie?’ It’s not a simple question to answer.

We also offer a limited number of factory rebuilt turbochargers.

When you consider that both rebuilt and brand-new turbochargers are fundamentally the same, what about a field overhauled unit, you might wonder.

However, the level of completeness of the overhaul is dependent on the shop performing the job.

If they adhere to the newest manuals, service bulletins, and service instructions for examining and overhauling HET turbochargers, valves, control units, and wastegates as well as replacing all of the necessary parts as specified, there is nothing wrong with them at all.

Mechanic, must complete your assignment.

If they are unable to provide one, move on to another store.

Components such as the turbine wheel are subjected to fatigue and heat stress throughout their operation.

That is why the overhaul handbook for HET recommends replacing vital components with new ones, which is the most logical course of action in this situation.

We have started a recommended service facility (RSF) program, which you can read about here.

HET RSFs are being employed by Quality Aircraft Accessories of Tulsa, Oklahoma ().

Hartzell Engine Technologies’ Tim Gauntt is the company’s director of product support.

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