Turbocharger Failure

Turbos fail for a reason, usually air or oil related. Here are the main causes of turbocharger failure:

  • Lack of lubricating oil or oil delay;
  • Foreign material or dirt in the lubricating system;
  • Oil break-down;
  • Foreign material in exhaust or air-filtration systems;
  • Material and workmanship

If the cause of turbo failure is not correctly diagnosed and rectified before fitting a replacement turbocharger it is likely the new turbo will suffer damage and fail for the same reason.  Click here to visit our Turbo Diagnostics pages for information that may help to identify the cause of a failed turbocharger and for help on how to rectify the causes of turbo failure.

 

Evidence of carbon build up in a 1.6 HDi PSA Group engine leading to total turbocharger failure

The PSA 1.6HDi, DV6TED4 engine is a highly sophisticated low emission, high power diesel engine and is used in many different applications; Citroen, Ford, Mazda, Mini, Peugeot and Volvo.

The following information applies to both the 753420-5005S Garrett turbo & 49173-07507 Mitsubishi turbo and also affects the following turbochargers:

Garrett: 753420-0001, 753420-0002, 753420-0003, 753420-0004, 753420-0005
MHI: 49173-07502, 49173-07504, 49173-07506, 49173-07507

Engine Type:  1.6 HDi PSA Group Engine –DV6TED4
Engine Year:  2007
Vehicle Year:  2007
Miles on Engine:  109,087
Miles on Original Turbocharger before replacement:  107,800 approx
Miles on 2nd Turbocharger before replacement:  937
Miles on 3nd Turbocharger before failure:  350
Service history:  Serviced by a main franchised dealer 2 times from new, at every 30,000 miles approx, and 3 times by an independent garage 3 times in total, every 15,000 miles.
Oil used at service:  Manufacturer ‘s recommended grade oil.
Notes:  Oil feed pipe changed during turbocharger replacement

This case study details an engine that has caused the failure of 2 new turbos in a short period of time. In an attempt to remove carbon particles that have caused the failure of the first turbo, this engine has been ‘flushed’ with an engine flush 2 times prior to strip down.

Click here to download the case study and complete overview of the oil contamination, particle build up & oil path restrictions in the engine and turbo leading to total failure of the turbocharger bearing system.

Carbonized oil is a major cause of failure of the turbo on this application!

Carbon may build up and may block oil feed to turbocharger. This can occur in, but is not limited to the following areas:

  • Filter at engine block
  • In-line filter on oil feed pipe to turbo
  • Oil return pipe from turbo to engine block
  • Internal oil galleries inside the engine block

Ensure to check all other areas for signs of carbon build up/ blockages.

The following components MUST also be replaced to prevent another turbo failure:

  • Oil feed lines
  • Oil return lines
  • Banjo bolts

Turbochargers fail for a reason, usually air or oil related. Before fitting a replacement turbo make sure to correctly diagnose and rectify the cause of the previous turbo failure.

Please ensure that engine has the latest specification of oil dipstick – turbo failure may be attributed to incorrect oil levels.

Click here for a checklist for correct turbocharger installation