Most turbocharger failures are caused by problems outside the turbocharger. If the turbocharger is defective, it is very important, in addition to replacing the turbocharger, to determine and eliminate the cause of the turbocharger failure, as the embedded turbocharger would not be broken again. Upon the recommendations of the world's largest turbocharger manufacturers Garrett, Holset, Borg Warner (KKK and Schwitzer), MHI and IHI, which we are an authorized service and distributor for the territory of Serbia and Montenegro, and based on twenty-five years of experience in turbocharger repair, your turbocharger has been inspected is the following:
Damage to the turbocharger is caused by the entry of a foreign particle into the compressor housing. The foreign particle damaged the compression wheel from the front, the input side which is reflected in breaking the blades. This damage causes the turbocompressor rotor debarment, and therefore the wear of bearings and sealing links of the turbocharger. As an end result we have oil consumption, the engine has no power, and there is a black or white smoke on the exhaust. This phenomenon is often accompanied by a buzz sound in the operation of the turbocharger. The foreign particle can be found in the suction branch due to damage to the air filters, due to the hole or cracks on the air intakes or if they have failed on the hose connections, or if the installation has not been cleaned during the previous overhaul of the turbocharger.
Damage to the turbocharger was due to the entry of a foreign particle into the rotary turbine circuits. A foreign particle could come from an engine block (a part of the valve, a heater seat or a guide), but also the same malfunction can also cause the inside of the exhaust branch to hide. Damage to the turbine rotor leads to a turbocompressor rotator impedance, and hence the wear of bearings and sealing links of the turbocharger, so oil consumption occurs, the engine does not have power, and there is a blue or blue smoke on the exhaust.
This phenomenon is often accompanied by a buzz sound in the operation of the turbocharger, and most often damage the compressor wheel. Before rebuilding the turbocharger, it is necessary to find out where the foreign particle came into the turbocharger and thus eliminate the cause of the fault.
Otherwise, the same damage will again occur. This means checking the exhaust branch and checking the engine condition.
The dismantling of the turbocharger detected a damage characteristic of the occurrence of partial or complete congestion of the exhaust gas pipe (exhaust pipe). Partial or complete conduction of the pipes creates a high pressure of the exhaust gases in the turbine housing, and since the exhaust gases can not unfasten the engine, they push the turbocharger forward to the compressor side. On the front side of the turbocharger, traces of unauthorized wear of the turbine wheel on the flame guard are visible, so the turbocharger leaks oil. All this causes loss of engine power and oil consumption, beige or blue smoke on the exhaust. The cause of the fault is a faulty (blocked) engine brake (faulty brake cylinder or a burning axle of the motor brake butterfly), or a foreign body blocked the exhaust.
Before reinstalling the turbocharger, the cause of the fault must be eliminated, which in this case is a motor brake and check the exhaust pipe.
On the passenger cars in the exhaust of the engine, a catalytic converter is installed. By the time of precipitation of the products of combustion, gargoyles and soot, there is a partial or complete congestion of the catalyst. Partial or complete concealment of the pipes creates a high pressure of exhaust gases in the turbine housing, and as in the previous case, this causes loss of engine power and oil consumption, blue or blue smoke at the exhaust and damage to the turbocharger rotor circuits.
The dismantled turbocharger has a breakdown in oil consumption, and according to the shape and type of component damage, it is reliably established that the engine on which this turbocharger is installed has the effect of high oil pressure in the engine crankcase. This malfunction of the turbocharger is accompanied by the symptoms of engine failure such as power loss, high oil consumption and beige or blue smoke at the exhaust. Characteristic signs of violent leakage are the appearance of "live oil" on the turbine side. The compressor housing is in the suction zone soiled with oil, so since the turbo is sucked in by the air, the oil can only come from the engine exhaust, so-called. "iberlaufa". If you inspect the intake hose, you will see that the oil extends from the vent to the turbocharger. Due to some problem on the engine there is increased pressure in the engine crankcase. Increased pressure raises the oil level in the crankcase, so the "live oil" appears on the engine exhaust and at the same time, since the turbocharger is connected to the engine crankcase through the oil outlet of the turbocharger, the oil pressure drives the sealing links in the turbocharger, so the oil violently passes on sealing carts even though they are not physically damaged. Over time, the increased oil pressure in the carter damages the seals of the turbocharger, so a turbocharger is required.
With the dismantling of the central assembly of the turbocharger, high wear of the sliding surfaces of the bearings and axles of the turbocharger was determined. Traces of wear - furrows in characteristic places, due to dirt in oil for lubrication, are clearly visible. The oil is contaminated with combustion products and shavings of engine parts. Depending on the degree of oil contamination, the gap between the bearings and the shaft increases, causing the sealing of the sealing links and the appearance of the turbocompressor turbine turbine, and even the blades of the turbine and compressor circuits on the turbocharger housing. The turbocharger consumes oil, the engine has no power, and there is a beo or black smoke on the exhaust. When installing the hose with the oil inlet and oil drain plugs, sealant masses must not be used, but the original seals must be used for this purpose.
In case of major repairs, such as general overhaul of the engine, when the engine is dismantled, often leftover shavings from overhaul get into the oil wear and the whole engine. Since the rotor trunks rotate once and 50 times faster than other shafts on the engine, the wear on the turbo is much larger and faster. After the completion of the general overhaul, it is necessary to rinse the engine crankcase well. Before reinstalling the turbine, the cause of the fault must be eliminated. It is necessary to replace the oil and oil filter and read out the engine crankcase, otherwise the same failure will again occur.
The dismantling of the central circuit of the turbocharger has caused damage to the sliding surfaces of the bearings and axles with the turbine wheel. In addition to traces of wear, a change in the color of the shaft at the wearing site is also characteristic. Poor lubrication or complete stop of lubrication, causes rapid wear and increase of the gap between the bearings and the shaft. Over time, the disbalance of the rotogrup is occurring, the wear of sealing links, and the turbo consumes oil. As a consequence of this rotor disbalance and damage to the blades of the impellers, the engine loses power, and a blue or black smoke appears on the exhaust. Often this fault is caused by the rotation of the turbocharger. The lubrication break may occur due to the blockage of the lubrication channels with large shavings in the oil, bale or engine failure.
Before re-installing the turbine, check the oil inlet hoses, replace the oil and oil filter and rinse the engine crankcase, otherwise the same failure will occur again.
By dismantling and reviewing turbocharger parts, it was found that the turbocharger failure occurred due to the rotation of the turbocharger over the allowed number of revolutions. In older types of turbochargers that do not have a VSG valve, this type of failure is due to a disruption in the combustion system, and then there is a higher pressure and an exhaust gas temperature than the predetermined one. At high rotational speeds of the rotor in the rotor material, there are internal stresses that cause the rotation of the rotor blades, the turbocharger bearings can not withstand such loads, and often the workload of the turbocharger rotor is broken. Turbocompressors equipped with a VSG valve are designed to operate at higher speeds than previously mentioned. The role of the VSG valve is that when the pressure of the exhaust gases in the turbocharger reaches a critical, maximum allowable value, it redirects the exhaust gases outside the rotation zone of the rotor and thus reduces the rotational speed of the turbocharger rotor.
In the new generation of turbochargers with variable geometry, in addition to the mentioned role, the VSG / solenoid valve regulates both the amount and the pressure of the exhaust gases during the operation of the turbocharger. In cases where the VSG valve is damaged or when the VSG valve is inaccessible, the rotor of the tubular compressor rotates with a higher number of revolutions than the maximum permissible. The engine consumes oil and loses power, and the turbocharger in operation has a beep sound. Often there is a breakdown of the turbocharger rotor due to internal loads. For turbochargers with variable geometry, there is damage to the rotor, the variable geometry and the central turbocharger housing, and the only solution is to replace the existing new turbocharger.
Damage to the turbine wheel with the axle is caused by excessive exhaust gas temperature. The cause of this turbocharger failure is at incorrect combustion in the engine. This malfunction is due to malfunction of the fuel supply system or improperly set-up of combustion. The high temperature on the axle shafts causes the burning of the oil, so we say that the oil "cokes". At high temperatures the material of the sealing links loses its properties, the wear of the bearings is accelerated and the turbocharger consumes oil. It also happens to be a fracture of a turbocharger rotor blade or a turbine casing. Burning or cracked turbine enclosure causes leakage of exhaust gases, so a buzz sound is heard in the work of the turbocharger, the engine has no power, and there is a black smoke on the exhaust. Before reinstalling, it is necessary to check the operation of the fuel supply system, and replace the oil and oil and air filters.
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