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E-mail: james@michiganturbo.com

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Wyoming, MI 49548

Phone: (616) 531-5126
Fax: (616) 531-0821

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Turbochargers • Turbos • Superchargers • Fan Blades & Clutches

Use the Troubleshooting Chart below to help diagnose the problems you
may be having with your Turbocharger!

A	Engine lacks power	Turbocharger Troubleshooting Loss of power, excess smoke, high fuel consumption, overheating, high exhaust temperatures, and oil leakages from the turbocharger are all symptoms that could indicate turbocharger malfunctions. These faults, however, are often wrongly attributed to the turbocharger, because defects in other components can produce the same symptoms. Since the turbocharger must be adjusted or regulated, only mechanical damage or blockage due to dirt can impair its performance. Before replacing a turbocharger, verify the problem and consult the chart below
B	Black exhaust smoke
C	Excessive engine oil consumption
D	Blue exhaust smoke
E	Turbocharger noisy
F	Cyclic sound from turbocharger
G	Oil leak from compressor seal
H	Oil leak from turbine seal

A	B	C	D	E	F	G	H	CAUSE	REMEDY
								Clogged air filter element	Replace element according to engine manufacturers recommendations
								Obstructed air intake duct to turbo compressor	Remove obstruction or replace damaged parts as required
								Obstructed air outlet duct from compressor to intake manifold	Remove obstruction or replace damaged parts as required
								Obstructed intake manifold	Refer to engine manufactures manual & remove obstruction
								Air leak in duct from air cleaner to compressor	Correct leak by replacing seals or tightening fasteners as required
								Air leak in duct from compressor to inlet manifold	Correct leak by replacing seals or tightening fasteners as required
								Air leak at intake manifold to engine joint	Refer to engine manufacturers manual & replace gaskets or tighten fasteners as required
								Obstruction in exhaust manifold	Refer to engine manufactures manual & remove obstruction
								Obstruction in muffler or exhaust stack	Remove obstruction or replace faulty components as required
								Gas leak in turbine inlet to exhaust manifold joint	Refer to engine manufacturers manual & replace gaskets or tighten fasteners as required
								Gas leak in turbine inlet to exhaust manifold joint	Replace gasket or tighten fasteners as required
								Gas leak in ducting after the turbine outlet	Refer to engine manufactures manual & repair leak
								Obstructed turbocharger oil drain	Remove obstruction or replace line as required
								Obstructed engine crankcase vent	Refer to engine manufacturers manual, clear obstruction
								Turbocharger center housing sludged or coked	Change engine oil & oil filter, overhaul turbocharger as required
								Fuel injection pump or fuel injectors incorrectly adjusted	Refer to engine manufacturers manual - replace or adjust faulty component(s) as required
								Engine camshaft timing incorrect	Refer to engine manufacturers manual & replace worn parts
								Worn engine piston rings or liners (blow by)	Refer to engine manufacturers manual & repair engine as required
								Internal engine problem (valves, pistons)	Refer to engine manufacturers manual & repair engine as required
								Dirt caked on compressor wheel and/or diffuser vanes	Clean using a Non-Caustic cleaner & Soft Brush. Find & correct source of unfiltered air & change engine oil &oil filter
								Damaged turbocharger	Analyze failed turbocharger, find & correct cause of failure, overhaul or replace turbocharger as required

COMMON CAUSES OF TURBO FAILURE

HOT SHUT DOWN. THAT IS, TURNING ENGINE OFF PREMATURELY WITHOUT ALLOWING SUFFICIENT TIME FOR TURBO TO COOL.
INFREQUENT OIL, OIL FILTER, AND AIR FILTER CHANGES.
FOREIGN MATTER AND / OR OBSTRUCTIONS IN TURBOCHARGER AIR OR OIL SYSTEM.
IMPROPER ENGINE MAINTENANCE. OPERATING ENGINE WHEN OUT OF TUNE OR IN NEED OF ADJUSTMENT OR MAINTENANCE.
RELATED ENGINE PART OR ENGINE FAILURE. FOR EXAMPLE, A CRACKED HEAD, BROKEN OR WORN PISTON RINGS, BLOWN HEAD GASKET, CLOGGED RADIATOR, AND IMPACT DAMAGE DUE TO ACCIDENT.

TURBO INSTALLATION GUIDE

CHECK THE OPERATION OF ENGINE TO ENSURE IT MEETS MANUFACTURER’S SPECIFICATIONS.
REPLACE OIL SUPPLY LINE IN ALL GASOLINE APPLICATIONS.
DO NOT USE A THREAD SEALER (SILICONE) ON ANY OIL LINE.
CHECK OIL DRAIN FOR RESTRICTIONS EFFECTING FLOW SUCH AS KINKED OR DETERIORATED RUBBER SECTIONS AND SHARP BENDS.
CHECK FOR CONTAMINATION AND OBSTRUCTIONS SUCH AS KINKED, WORN, AND PLUGGED OIL LINES AND OIL PASSAGES. IF APPLICABLE, CHECK INTER OR AFTER COOLER FOR THE SAME. REMOVE AND THOROUGHLY CLEAN INTERCOOLER.
REPLACE AIR FILTER ELEMENT. CHECK FOR FLOW RESTRICTIONS IN BOTH INTAKE, AND EXHAUST, INCLUDING CATALYTIC CONVERTER.
INSPECT FOR AND REMOVE ALL FOREIGN OBJECTS FROM THE INTAKE AIR TRACT, AND SECURE ALL HOSES.
REPLACE OIL AND OIL FILTER. REPLACE ANY CRANKCASE BREATHER ELEMENTS.
VERIFY THAT THE ACTUATOR “C” CLIP IS SECURE.
VERIFY OIL DRAIN DIRECTION IS VERTICAL.
VERIFY TIGHTNESS OF ALL CLAMPS AND BOLTS, SECURE LOCK TABS IF APPLICABLE.
AFTER INSTALLATION, ENSURE TO REMOVE ALL TOOLS FROM ENGINE COMPARTMENT.
BEFORE STARTING ENGINE, DISABLE EITHER FUEL OR IGNITION SYSTEM TO ALLOW ENGINE TO BE CRANKED WITHOUT STARTING. ENGINE MUST BE CRANKED UNTIL NORMAL OIL PRESSURE IS ACHIEVED. ONCE OIL PRESSURE IS ACHIEVED, THEN YOU MAY START ENGINE. REPEAT AFTER ALL OIL CHANGES.

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	Function of a Turbocharger Power output is determined by the amount of fuel that can be burned in a given time. For proper combustion, the fuel needs an adequate supply of air. To increase power more air is required. Since the volume of the engine cylinders is fixed, the air supply can only be increased by using some form of compressor. The turbocharger increases the air supply by means of a compressor driven by the waste exhaust gases. Since the exhaust gas energy is used to improve the overall efficiency of the engine, the fuel consumption is reduced resulting in LOWER operating expenses.
YOUR TURBOCHARGER'S WORST ENEMIES
CONTAMINATED LUBRICANT.... Bad lubricant will cause scored shaft journals and bearings, block oil holes and plug seals, resulting in heavy oil leakage.
FOREIGN OBJECT INGESTION.... Damages turbine and compressor wheel blades, causing wheel imbalance and rotational instability, with resulting damage to seal bores and bearings
ENGINE PIECES, SHOP TOWELS, SAND, DIRT OR METAL FILINGS.... These are all externally-introduced causes of turbocharger failure, and as such, can be lessened or eliminated through proper maintenance of engine air intake and oil filtering systems.
YOUR TURBOCHARGER'S BEST FRIEND!
CLEAN LUBRICANT.... Always be sure to keep your turbocharger well maintained with a good quality lubricant. It will prolong its life and enhance its performance.
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