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CONTEXT
DISCLAIMER:
Our pictorials are of informative nature and do illustrate works carried out by ourselves at our own premises for our own use and satisfaction. Readers who envisage to carry out similar works inspired by the below method shall do this at their own risks and liability. |
A turbo failure due to absence of lube oil:
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The below tutorial explains how to troubleshoot a failing turbo focusing on its environment and looking for the causes behind its failure:
- Turbo failure due to motor oil choice
- Turbo failure due to cooling problems
1- Troubleshooting turbo problems resulting from engine oil
The below pictures show that oil got burnt, carbonized and clogged the turbo lube tube leading to permanent damage to the turbo bearing;
From left to right: before even dismantling any mechanical component, we removed the easily accessible banjo-bolt of the lube tube. this picture shows it was found completely dry, meaning no oil is reaching the turbo.
After turbo removal (click to see related page), the oil return tube was also found perfectly dry.
If you face such unfortunate case, keep in mind that the lube supply tube cannot be cleaned, cutting it will show that carbonized oil has clogged the tube on some 20 cm distance. It is a hard, glass like compound that cannot be removed mechanically or chemically.
From left to right: before even dismantling any mechanical component, we removed the easily accessible banjo-bolt of the lube tube. this picture shows it was found completely dry, meaning no oil is reaching the turbo.
After turbo removal (click to see related page), the oil return tube was also found perfectly dry.
If you face such unfortunate case, keep in mind that the lube supply tube cannot be cleaned, cutting it will show that carbonized oil has clogged the tube on some 20 cm distance. It is a hard, glass like compound that cannot be removed mechanically or chemically.
Since there is a clear oil problem, we checked the engine oil elsewhere before going further.
We opened the oil replenishment cover and looked inside, also drained the motor oil to see what goes down.
We opened the oil replenishment cover and looked inside, also drained the motor oil to see what goes down.
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Engine cylinder head was found black i.e. completely covered with a thickened but soft coat of oil. Oil drains well with no sludge going out of the sump. The oil type used in this engine seems to be too thick meaning of a wrong viscosity and its performance at high temperatures limited. The clean sump is to be read positively since the trouble is at cylinder head only.
We then removed the oil filter base where the turbo oil return pipe is connected to check if anything is clogged in there.
We cleaned all parts, including the oil pressure switch using gasoline for the filter body and sensor cleaner spray for the switch.
We then removed the oil filter base where the turbo oil return pipe is connected to check if anything is clogged in there.
We cleaned all parts, including the oil pressure switch using gasoline for the filter body and sensor cleaner spray for the switch.
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2- Troubleshooting turbo cooling pipes and turbo cooling pump
Because oil was found disintegrating and carbonizing under the effects of high temperatures, we focused on the turbo cooling to make sure all works well. If you do so, you should look first if some coolant dropped out of the hoses when dismantling them despite having drained it. Hose ends should be wet and some minimum quantity of coolant should have remained trapped inside.
Inspect the banjo-bolts which should be clear and clean.
Inspect the banjo-bolts which should be clear and clean.
If the turbo is equipped with an additional electrical water pump for further cooling after engine stops, test the pump by powering it directly from the battery (picture to the left). Do not leave it running dry for a long period, just a few seconds to make sure it rotates with a steady and homogeneous sound.
Clean the engine inlets and outlets that connect to the oil filter assembly. Replace the gasket before re-assembling or if you're working on Sunday and did not plan to buy this gasket, use a thin coat of high temperature silicone gasket maker. A particular care is to be observed not to let coolant and oil circuits mix. Do not use excess silicone, and make sure to cover well the existing gasket all over its length, all around the holes.
Clean the engine inlets and outlets that connect to the oil filter assembly. Replace the gasket before re-assembling or if you're working on Sunday and did not plan to buy this gasket, use a thin coat of high temperature silicone gasket maker. A particular care is to be observed not to let coolant and oil circuits mix. Do not use excess silicone, and make sure to cover well the existing gasket all over its length, all around the holes.
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3- Recap of turbo failure causes, diagnosis and how to fix them
Oil specifications:
Oil is found to be of the wrong choice: necessity to use a lower viscosity and higher flash point oil (the higher the flash point, the higher its ability to withstand elevated temperatures). It has to be full synthetic. See our motor oil comparison page, our introduction to ACEA motor oil standards and our motor oil grades chart.
Oil change and Air Filter interval:
If you had followed your vehicle's manual and replaced oil at long intervals (15 or 20,000 Km), cut this interval to 10,000.
Do the same for the Air Filter.
See also:
Oil is found to be of the wrong choice: necessity to use a lower viscosity and higher flash point oil (the higher the flash point, the higher its ability to withstand elevated temperatures). It has to be full synthetic. See our motor oil comparison page, our introduction to ACEA motor oil standards and our motor oil grades chart.
Oil change and Air Filter interval:
If you had followed your vehicle's manual and replaced oil at long intervals (15 or 20,000 Km), cut this interval to 10,000.
Do the same for the Air Filter.
See also:
Other problems resulting from the oil breakdown:
Cylinder head was found heavily contaminated with sludge. See related page for desludging. It is mandatory to clean the cylinder head at the earliest.
Cylinder head was found heavily contaminated with sludge. See related page for desludging. It is mandatory to clean the cylinder head at the earliest.
Parts to replace to guarantee a long lifetime for the new turbo:
Replace, turbo, turbo to manifold gasket, turbo to catalytic converter gasket, oil supply tube, oil return hose, oil supply banjo-bolt, all copper ring seals of the three banjo-bolts, oil filter, oil, oil change plug washer seal. Click here to visit the turbo replacement page.
What to do with the dismantled turbo:
Do not throw it away! Buy a new "cartridge" and have it back like new. Keep it as a spare.
Replace, turbo, turbo to manifold gasket, turbo to catalytic converter gasket, oil supply tube, oil return hose, oil supply banjo-bolt, all copper ring seals of the three banjo-bolts, oil filter, oil, oil change plug washer seal. Click here to visit the turbo replacement page.
What to do with the dismantled turbo:
Do not throw it away! Buy a new "cartridge" and have it back like new. Keep it as a spare.
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