Visual & Mechanical Checks

CAUTION: Do not run the engine during these procedures. If the engine has been running, make sure it is cool before beginning.

Warning! Operating the turbocharger without the inlet duct and air filter connected can result in personal injury. Equipment damage may result from foreign objects entering the turbocharger.

The basic steps to troubleshooting are as follows:

1. VISUAL AND MECHANICAL CHECKS

Inspect the turbocharger exterior and installation. Listen for unusual mechanical noises. Visually check and test for leaks, blockage, high heat, restrictions or conditions that have allowed wheels to contact the housings. Leaks that are seemingly small and insignificant at idle or low power can greatly affect air/fuel ratios and pressures within the housing and full power. At full power, those leaks become problematic.

a. Listen for unusual mechanical noise and watch for vibration.

b. Listen for a high pitched noise. It can indicate air or gas leaks.

c. Listen for noise level cycling. It can indicate a restriction in the air cleaner or ducting.

d. Inspect for missing or loose nuts, bolts, clamps and washers.

e. Inspect for loose or damaged intake and exhaust manifolds and their ducting and clamps.

f. Inspect for damaged or restricted oil supply and drain lines.

g. Inspect for cracked or deteriorating turbocharger housings.

h. Inspect for external oil or coolant leakage; external din deposits (indicates air, oil, exhaust or coolant leakage).

i. Inspect for obvious heat discoloration.

j. Inspect for obviously restricted air filter.

k. Check the wastegate for free movement and damage. Be sure that hoses are in good condition and that the connections are tight. Check the calibration and control system according to the original equipment specifications.

l. Verify that the turbocharger is the correct configuration for the application.

Remember, correcting these problems does not in it self remove any residues that were the indicators of the problem. The remaining residues often cause inaccurate turbocharger evaluation. Incorrect turbocharger evaluation may result after the situation has been corrected and the residues remain. For example, an air filter replaced just previous to your inspection would lead you to conclude that air blockage is not the problem even though the residue indicates blockage.

Correct any installation problems after completing the rest of this procedure. If turbocharger parts are damaged, then the unit should be replaced at this time and corrective actions taken to prevent reoccurrence.

Refer to the engine manufacturer's service instructions for inspection requirements and replacement specifications.