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Causes for turbo damages

The causes for turbo damages usually fall into the following four categories:

 Lack of Lubrication or Oil Starvation:

Turbo fatigue cracking and material transfer created by metal friction and high temperatures as a result of oil inlet supply restrictions, incorrect gasket placement and use of liquid gaskets or poor quality lubricants.

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Causes:

- Low engine oil levels

- Obstructions in oil feed lines

- Build up of burnt oil in center housing

- Excessive Temperature

- Inferior oil quality

- Low engine oil levels

Symptoms:

- Oil leakage

- Noise

- Loss of power

- Excessive smoke

- Excessive oil consumption

Consequences:

- Excessive wear of journal bearings, thrust bearing, and thrust collar

- An imbalance causing excessive wear to rotating components

- Wear of sealing surfaces of back plate and thrust collar

- Piston ring failure or leakage

 

Oil Contamination:

Turbo bearing system damage caused by a high concentration of carbon suspended in oil, created by extended oil change intervals or poor maintenance. Bearing damage caused by a steel shot suspended in oil following a major engine overhaul.failure-02.png

 Causes:

- Saturated oil filter

- Recycled Oil

- A rebuilt engine with impurities within the oil passages

- Burnt oil from high temperatures

 Symptoms:

- Oil leakage

- Noise

- Loss of power

- Excessive smoke

- Excessive oil consumption

Consequences:

- Scoring and wear of journal bearings

- Scoring and wear of thrust bearing and thrust collar

- Imbalance

- Failed components

Foreign Objects:

Turbo wheel damage, caused by small objects entering the turbine or compressor housing at high speed, leading to imbalance.failure-03.png

Causes:

- Materials ingested into either the compressor ,or turbine side of the turbo

- Damage to the compressor side suggests an insufficient/dirty air filtration system, or a

damaged air intake tubes

- Damage to the turbine suggests damage to the engine such as parts of the pistons ,or valves

 Symptoms:

- Loss of power

- Noise

- Excessive smoke

Consequences:

- Damage to the wheels

- Imbalance to the rotating assembly

- Excessive wear to the rotating assembly

Hot Shutdown:

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Causes:

- Frequent turning off the engine at high speed

- Inferior oil quality

- High operating temperature

Symptoms:

- Oil leakage

- Excessive smoke

Consequences:

- Extensive deposits of carbon and shellac in the turbine end seal parts and bearing system

- In early stages of failure, bearing clearances are decreased by the deposits

- As the problem continues, the deposits break up, scoring and wearing the

bearing bore, journal bearing, and shaft.

Overspeed and Excessive Temperature:

Turbo damage caused by working beyond its designed parameters or outside the vehicle manufacturer's specification. Maintenance problems, engine malfunction or unauthorized performance upgrades can push turbo rotating speeds beyond its operating limits, causing fatigue failure or compressor and turbine wheels.

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Causes:

- Incorrect engine air/fuel ratios

- Malfunctioning exhaust oxygen sensor or other engine control system

- Malfunctioning wastegate actuator or its wrong calibration

- Application not in accordance to the standards

Symptoms:

- Loss of power

- Noise

- Oil leakage

Consequences:

- Scoring the wheels to the housings

- Imbalance to the rotating assembly

- Excessive wear to the rotating assembly


Excessive Exhaust Gas Temperature:

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Causes:

- Engine operation in altitude

- Incorrect engine air/fuel ratios

- Malfunctioning exhaust oxygen sensor or other engine control system

- Malfunctioning EGR valve

Symptoms:

- Loss of power.

- Noise.

- Excessive smoke

- Oil leakage.

Consequences:

- Erode, distort, or crack the turbine housing

- Wheels rub the end housings

- Imbalance to the rotating assembly

- Thrust bearing / journal bearing collapses