Turbocharger Troubleshooting

Figure 1:

Refer to Figure 1.

ABNORMAL NOISE (noisy, bearing damage, blade interference)

1. Inspect fixing bolts, center housing to turbine housing bolts, and wastegate.

^ RESULT: Bolts are missing, or wastegate is binding due to rust.
^ ACTION: Replace turbocharger.
^ RESULT: All bolts are present and wastegate is in good condition.
^ ACTION: Go to step 2.

2. Remove air intake hose. Inspect the compressor wheel.

^ RESULT: Compressor wheel blades are damaged.
^ ACTION: Replace turbocharger.
^ RESULT: Compressor wheel blades are in good condition.
^ ACTION: Go to step 3.
3. Check movement of shaft.

^ RESULT: Shaft moves enough to allow compressor or turbine wheel to contact housing. (This indicates worn bearings.)
^ ACTION: Replace turbocharger.
^ RESULT: Shaft movement doesn't allow wheel-to-housing contact.
^ ACTION: Go to step 4.

4. Start the engine and check for turbocharger noise.

^ RESULT: Abnormal noise present.
^ ACTION: Check for exhaust gas leak at exhaust pipe joint.
^ RESULT: Exhaust gas leak present.
^ ACTION: Replace gasket if damaged. Tighten any loose bolts.
^ RESULT: No exhaust gas leak observed.
^ ACTION: Turbocharger is OK. Check for mechanical engine problems that may be causing abnormal noise.
^ RESULT: No abnormal noise noted.
^ ACTION: Turbocharger is OK.
OIL LEAKAGE (white smoke, high oil consumption, or defective seal)

1. Check for oil leakage at points A, B, C, D and E. (See Figure 1)

^ RESULT: Oil leakage present at point B.
^ ACTION: Replace gasket if damaged. Tighten loose bolts.
^ RESULT: Oil leakage present at point D.
^ ACTION: Check engine for mechanical damage or wear causing oil in exhaust. Specifically, check piston rings and/or intake valve seals.
^ RESULT: Oil leakage present at point A, C or E.
^ ACTION: Inspect turbocharger oil return pipe for dainage.
^ RESULT: Damaged oil return pipe.
^ ACTION: Replace oil return pipe.
^ RESULT: Oil return pipe is in good condition.
^ ACTION: Go to step 2.
^ RESULT: No oil leakage present.
^ ACTION: Go to step 2.

2. Check PCV system for blockage.

^ RESULT: PCV system is blocked.
^ ACTION: Repair or replace PCV valve and/or hoses.
^ RESULT: PCV system is OK.
^ ACTION: Go to step 3.

3. Remove air intake hose and inspect the compressor wheel.

^ RESULT: Oil deposits on compressor wheel blades.
^ ACTION: Check PCV system. Check for hose blockage around oil separator.
^ RESULT: Compressor wheel is damaged.
^ ACTION: Replace turbocharger. Correct problem allowing foreign material to enter the intake system.
^ RESULT: Compressor wheel is clean and undamaged.
^ ACTION: Go to step 4.

4. Turn the shaft by hand.

^ RESULT: Shaft movement is heavy. (Carbon build-up at seal.)
^ ACTION: Replace turbocharger.
^ RESULT: Shaft moves enough to allow compressor or turbine wheel to contact housing. (This indicates worn bearings.)
^ ACTION: Replace turbocharger.
^ RESULT: Shaft moves normally.
^ ACTION: Go to step 5.

5. Start the engine and check the exhaust smoke.

^ RESULT: White exhaust smoke is present.
^ ACTION: Replace turbocharger.
^ RESULT: Exhaust is normal.
^ ACTION: Turbocharger is OK.

POOR PERFORMANCE (lack of boost, runs rough or hesitation)

1. Check operation of gauges (tachometer, boost gauge, etc.).

^ RESULT: Gauges are operating improperly.
^ ACTION: Repair or replace the appropriate gauge(s).
^ RESULT: Gauges are operating correctly.
^ ACTION: Go to step 2.

2. Check electrical system components (ECM, sensors, etc.)

^ RESULT: Electrical component(s) operating improperly.
^ ACTION: Replace appropriate component(s).
^ RESULT: Electrical components OK.
^ ACTION: Go to step 3.

3. Inspect rubber hoses.

^ RESULT: Hoses cracked.
^ ACTION: Replace cracked hoses.
^ RESULT: Hoses in good condition.
^ ACTION: Go to step 4.

4. Inspect engine and turbocharger fixing bolts.

^ RESULT: Fixing bolts loose.
^ ACTION: Check for damaged gaskets and replace if necessary. Tighten fixing bolts.
^ RESULT: Fixing bolts OK.
^ ACTION: Go to step 5.
5. Inspect condition of turbocharger wastegate.

^ RESULT: Wastegate is rusty or deformed.
^ ACTION: Replace turbocharger.
^ RESULT: Wastegate hose is cracked.
^ ACTION: Replace wastegate hose.
^ RESULT: Wastegate is in good condition.
^ ACTION: Go to step 6.

6. Remove air intake hose and inspect for compressor wheel damage.

^ RESULT: Compressor wheel is damaged.
^ ACTION: Replace turbocharger.
^ RESULT: Compressor wheel is not damaged.
^ ACTION: Go to step 7.

7. Turn the shaft by hand.

^ RESULT: Shaft movement is heavy. (Carbon build-up at seal.)
^ ACTION: Replace turbocharger.
^ RESULT: Shaft moves normally.
^ ACTION: Go to step 8.
8. Check movement of shaft.

^ RESULT: Shaft moves enough to allow compressor or turbine wheel to contact housing.
^ ACTION: Replace turbocharger.
^ RESULT: Shaft movement doesn't allow wheel-to-housing contact.
^ ACTION: Go to step 9.

9. Start the engine and check the intake pressure.

^ RESULT: Intake pressure is abnormal.
^ ACTION: Inspect engine as outlined in the appropriate Workshop Manual.
^ RESULT: Intake pressure is abnormal. ^ACTION: Turbocharger is OK.