Turbocharger Identification
Before ordering a replacement turbocharger it is important to identify the turbochargers part number. Many applications have several different turbocharger variations even when narrowed down to the year and engine type. Therefore the turbocharger part number should be acquired whenever possible.
Each turbocharger should have an identification plate attached to it detailing the part number and the model number. This plate is in various postitions depending on the type of turbocharger
Turbocharger I.D. Tags
Garrett Turbochargers are formatted as follows:
7#####-00## or 4#####-00##
Garrett turbo part numbers are found on a small aluminium plate or etched onto a flat surface on the aluminium intake housing.
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KKK Turbochargers are formatted as follows: K14 to K32 are written in full as example below:
5316-970-6723
K03 and K04 turbochargers are abbreviated on the turbocharger tag as follows:
K03-3 or K03-03 = part number 5303-970-0003
KKK turbo part numbers are placed on an auminium plate on the front or rear of the aluminium intake housing.
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Holset Turbochargers are formatted:
35#####
Holset Part numbers are place on an aluminium tag close to the air outlet of the compressor housing.
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Mitsubishi or MHI Turbochargers are formatted:
4####-0####
Mistsbishi turbochargers have the part number made up of a combination of cast and stamped numbers on the aluminium intake housing. Some mitsubishi turbochargers such as those fitted to Saab and Volvo may have an aluminium plate riveted onto the air intake housing instead.
Turbocharger Fitting
Correct turbocharger fitment involves more than following the turbocharger fitting instructions that are specific and supplied with each turbocharger. When a turbocharger has failed the fault diagnosis does not stop there. Far more important is the reason for failure. Most turbochargers fail for a reason; the most popular cause of failure are oil related problems.
Other causes such as overboosting, overspeeding and foreign object impact damage are all common turbocharger failure causes. Any fault that will prejudice the operation of the turbocharger must be found and rectified before fitment of another turbocharged is carried out.
The chart below provides only a guideline to various causes of incorrect turbocharger operation. As the chart illustrates, many faults are outside the operation of the turbocharger, which is not always the cause of the fault.
A turbocharger is not an independent device unlike other ancillary components on a vehicle, such as a power steering pump for example. It is an intrinsic part of the vehicle's power system. It shares with the engine it's oil supply, water supply, air intake supply, exhaust gas flow, engine management control, various pneumatic devices, ignition and fuel injection devices. Any and all of these have a crucial effect on the operation of the turbocharger. The culmination of these variables can result in a relatively complicated task in accurate turbocharger fault diagnosis. It is for this reason that sufficient time and understanding must be applied to turbocharger fault investigations.
Turbocharger 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
Fault Diagnosis
| |
Cause | Remedy |
Worn internal engine components | Repair engine as required |
Fuel system defective or incorrectly adjusted | Replace or adjust faulty components |
Low boost | Check wastegate and actuator operation |
Damaged turbocharger | Determine reason for failure - repair or replace turbo |
Air filter blocked | Replace air filter |
Air pipe into turbo restricted | Replace pipe |
Air pipe from filter to turbo leaking | Check hoses for splits and tighten hose clips |
Air pipe from turbo to inlet manifold leaking | Check hoses and intercooler for leaks and replace |
Ignition timing incorrectly adjusted | Check and reset |
Blockage in exhaust system | Replace silencers or catalytic converter |
Exhaust gas leaking from manifold | Replace gasket or manifold - check bolts for tightness |
| |
Cause | Remedy |
Damaged turbocharger | Determine reason for failure - repair or replace turbo |
Air pipe into turbo restricted | Replace pipe |
Air pipe from filter to turbo leaking | Check hoses for splits and tighten hose clips |
Air pipe from turbo to inlet manifold leaking | Check hoses and intercooler for leaks and replace |
Carbon build-up in turbo bearing housing | Change engine oil and filter-overhaul or replace turbo |
Blockage in exhaust system | Replace silencers or catalytic converter |
Exhaust gas leaking from manifold | Replace gasket or manifold - check bolts for tightnes |
Symptom : Excessive Engine Oil Consumption | |
Cause | Remedy |
Worn internal engine components | Repair engine as required |
Fuel system defective or incorrectly adjusted | Replace or adjust faulty components |
Damaged turbocharger | Determine reason for failure - repair or replace turbo |
Air filter blocked | Replace air filter |
Air pipe into turbo restricted | Replace pipe |
Incorrect operation of crankcase breather system | Check breather hoses, pipes and one way valves as per manufacturers recommendations |
Carbon build-up in turbo bearing housing | Change engine oil and filter-overhaul or replace turbo |
Air pipe from turbo to inlet manifold leaking | Check hoses and intercooler for leaks and replace |
Restricted oil drain pipe from turbocharger | Replace oil drain pipe |
| |
Cause | Remedy |
Worn internal engine components | Repair engine as required |
Fuel system defective or incorrectly adjusted | Replace or adjust faulty components |
Damaged turbocharger | Determine reason for failure - repair or replace turbo |
Air filter blocked | Replace air filter |
Air pipe into turbo restricted | Replace pipe |
Restricted oil drain pipe from turbocharger | Replace oil drain pipe |
Incorrect operation of crankcase breather system | Check breather hoses, pipes and one way valves as per manufacturers recommendations |
Carbon build-up in turbo bearing housing | Change engine oil and filter-overhaul or replace turbo |