Turbocharger Failure Analysis Chart

Engine Lacks Power	Black Exhaust Smoke	Excessive Engine Oil Consumption	Blue Exhaust Smoke	Turbo Noisy	Cyclic sound from turbo	Oil Leak from compressor seal	Oil Leak from turbine seal	Cause	Remedy
				.	.		. .	Clogged air filter	Replace air filter
.							.	Obstructed air intake to turbo	Remove Obstruction
		.	.		.	.	.	Obstructed air outlet duct from compressor to intake manifold	Remove Obstruction
		.	.		.	.	.	Obstructed intake	Remove Obstruction
.	.	.	.		.	.	.	Air leak in duct from air cleaner to compressor	Replace seals or tighten fasteners
					.	.	.	Air leak in duct from compressor to intake manifold	Replace seals or tighten fasteners
					.	.	.	Air leak at intake manifold to engine joint	Replace seals or tighten fasteners
					.		.	Obstruction in exhaust manifold	Remove Obstruction
		.	.	.	.		.	Obstruction in muffler or exhaust stack	Remove Obstruction
		.	.		.		.	Gas leak in exhaust manifold to engine joint	Replace seals or tighten fasteners
		.	.		.		.	Gas leak in turbine inlet to exhaust manifold joint	Replace seals or tighten fasteners
.	.	.	.		.	.	.	Gas leak in ducting after turbine outlet	Repair gas leak
.	.			.	.			Obstructed turbo oil drain line	Remove obstruction or replace oil drain line
.	.			.	.			Obstructed engine crankcase vent	Clear obstruction
.	.			.	.			Turbo center housing sledged or coked	Change engine oil, filter, replace turbo as required
		.	.	.	.	.	.	Fuel injection pump or injectors incorrectly adjusted	Replace or adjust injectors and/or injection pump
		.	.	.	.	.	.	Engine camshaft timing incorrect	Check/reset timing
				.	.			Worn engine rings or liners (blowby)	Repair as needed
				.	.			Internal engine problem (valves, pistons)	Repair as needed
								Dirt caked on compressor wheel	Clean with non caustic cleaner and soft brush, change filters
								Damaged turbo	Analyze turbo to determine failure, replace turbo
Turbocharger Installation Check List
	Replace oil supply lines and fittings. These lines often become plugged with decomposed oil which restricts oil flow and drainage.
	Do not used silicone or thread tape
	Make sure all openings to turbo are open and not plug or capped off.
	Shut off fuel or disable ignition and crank the engine for at least 15 seconds or until oil pressure is raised
	Allow engine to fast idle (1,000 RPM) for 3 - 5 minutes to seat turbo seals
	Always let engine idle for 3 -5 minutes before shut down, otherwise the turbo will continue to spin without oil lubrication and pressure
	When changing oil, be sure to prime oil filter