TURBO TROUBLESHOOTING TOOL
Problem with your turbo? Select a symptom below!
| Possible Cause | Solution |
| Did you know? | Nearly all turbocharger-related problems are the result of a handful of causes. Knowing how to recognize the symptoms of these issues early and link them with causes will help you save (down) time and money. |
| Possible Cause | Solution |
| Dirty air cleaner element | Clean or replaced filter element |
| Collapsed or restricted air pipe before turbocharger | Inspect pipe for damage or obstructions, replace or repair |
| Restricted or damaged crossover pipe turbo to inlet manifold | Inspect pipe for damage or obstructions, replace or repair |
| Foreign object between cleaner and turbocharger | Inspect air intake piping, remove foreign object |
| Foreign object in exhaust system (from engine, check engine) | Inspect exhaust piping ONLY when engine is NOT running and cold, remove foreign object |
| Turbocharger flanges, clamp or bolt loose | Inspect all connecting hardware for damage, ensure tight fits per installation instructions |
| Inlet manifold cracked, gaskets loose or missing, connections loose | Remove and inspect inlet manifold for damage to castings and gaskets, replace if needed |
| Exhaust manifold cracked, burned, gasket loose, blown or missing | Remove exhaust manifold ONLY when engine is cold and NOT running and inspect for damage to castings and gaskets, replace if needed |
| Turbine housing damaged or restricted | Remove turbine housing, inspect for cracks or wear, replace if needed |
| Worn jounal bearing | Contact the number on the front of this brochure |
| Excessive dirt build-up behind turbine wheel | Inspect air cleaner element and intake piping for damage or leaks, replace if needed. Clean compressor wheel and housing |
| Excessive carbon build-up behind turbine wheel | Inspect crankcase ventilation system |
| Fuel pump malfunction | Refer to engine manufacturer’s manual and replace if needed |
| Worn or damaged injectors | Inspect injectors for damage and replace if needed |
| Valve timing | Refer to engine manufacturer’s manual and adjust as needed |
| Burned valves | Refer to engine manufacturer’s manual and replace if needed |
| Worn piston rings | Refer to engine manufacturer’s manual and replace if needed |
| Burned pistons | Refer to engine manufacturer’s manual and replace if needed |
| Oil bath air cleaner: air inlet screen restricted / dirty air cleaner | Repair air inlet screen |
| Oil bath air cleaner: oil pull-over / oil viscocity too low or high | Replace lubricating oil with correct grade |
| Boost control malfunction: wastegate | Inspect for damage, leaks or obstructions; replace or repair if needed |
| Boost control malfunction: VNT | Contact us right away |
| Boost control malfunction: engine management system | Refer to engine manufacturer’s manual and adjust as needed |
| Possible Cause | Solution |
| Dirty air cleaner element | Clean or replaced filter element |
| Collapsed or restricted air pipe before turbocharger | Inspect pipe for damage or obstructions, replace or repair |
| Restricted or damaged crossover pipe turbo to inlet manifold | Inspect pipe for damage or obstructions, replace or repair |
| Foreign object between cleaner and turbocharger | Inspect air intake piping, remove foreign object |
| Foreign object in exhaust system (from engine, check engine) | Inspect exhaust piping ONLY when engine is NOT running and cold, remove foreign object |
| Turbocharger flanges, clamp or bolt loose | Inspect all connecting hardware for damage, ensure tight fits per installation instructions |
| Inlet manifold cracked, gaskets loose or missing, connections loose | Remove and inspect inlet manifold for damage to castings and gaskets, replace if needed |
| Exhaust manifold cracked, burned, gasket loose, blown or missing | Remove exhaust manifold ONLY when engine is cold and NOT running and inspect for damage to castings and gaskets, replace if needed |
| Turbine housing damaged or restricted | Remove turbine housing, inspect for cracks or wear, replace if needed |
| Worn jounal bearing | Contact the number on the front of this brochure |
| Excessive dirt build-up behind turbine wheel | Inspect air cleaner element and intake piping for damage or leaks, replace if needed. Clean compressor wheel and housing |
| Excessive carbon build-up behind turbine wheel | Inspect crankcase ventilation system |
| Fuel pump malfunction | Refer to engine manufacturer’s manual and replace if needed |
| Worn or damaged injectors | Inspect injectors for damage and replace if needed |
| Valve timing | Refer to engine manufacturer’s manual and adjust as needed |
| Burned valves | Refer to engine manufacturer’s manual and replace if needed |
| Worn piston rings | Refer to engine manufacturer’s manual and replace if needed |
| Burned pistons | Refer to engine manufacturer’s manual and replace if needed |
| Oil bath air cleaner: air inlet screen restricted / dirty air cleaner | Repair air inlet screen |
| Oil bath air cleaner: oil pull-over / oil viscocity too low or high | Replace lubricating oil with correct grade |
| Boost control malfunction: wastegate | Inspect for damage, leaks or obstructions; replace or repair if needed |
| Boost control malfunction: VNT | Contact us right away |
| Boost control malfunction: engine management system | Refer to engine manufacturer’s manual and adjust as needed |
| Possible Cause | Solution |
| Plugged crankcase breathers | Clear obstruction per manufacturer’s manual |
| Turbocharger flanges, clamp or bolt loose | Inspect all connecting hardware for damage, ensure tight fits per installation instructions |
| Restricted oil drain line | Remove and inspect oil line, remove obstruction |
| Turbocharger seal leakage | Inspect for proper oil feed / drain line installation. Contact the number on the front of this brochure for a rebuild. |
| Worn jounal bearing | Contact the number on the front of this brochure |
| Excessive engine idle | Refer to engine manufacturer’s manual and adjust as needed |
| Coked or sludged center housing | Contact us right away |
| Oil filter plugged | Refer to engine manufacturer’s manual and replace if needed |
| Oil bath air cleaner: air inlet screen restricted / dirty air cleaner | Repair air inlet screen |
| Oil bath air cleaner: oil pull-over / oil viscocity too low or high | Replace lubricating oil with correct grade |
| Boost control malfunction: wastegate | Inspect for damage, leaks or obstructions; replace or repair if needed |
| Boost control malfunction: VNT | Contact us right away |
| Boost control malfunction: engine management system | Refer to engine manufacturer’s manual and adjust as needed |
| Possible Cause | Solution |
| Dirty air cleaner element | Clean or replaced filter element |
| Collapsed or restricted air pipe before turbocharger | Inspect pipe for damage or obstructions, replace or repair |
| Turbocharger flanges, clamp or bolt loose | Inspect all connecting hardware for damage, ensure tight fits per installation instructions |
| Inlet manifold cracked, gaskets loose or missing, connections loose | Remove and inspect inlet manifold for damage to castings and gaskets, replace if needed |
| Turbocharger seal leakage | Inspect for proper oil feed / drain line installation. Contact the number on the front of this brochure for a rebuild. |
| Excessive dirt build-up behind turbine wheel | Inspect air cleaner element and intake piping for damage or leaks, replace if needed. Clean compressor wheel and housing |
| Excessive carbon build-up behind turbine wheel | Inspect crankcase ventilation system |
| Excessive engine pre-oil | Refer to engine manufacturer’s manual and adjust as needed |
| Excessive engine idle | Refer to engine manufacturer’s manual and adjust as needed |
| Coked or sludged center housing | Contact us right away |
| Oil filter plugged | Refer to engine manufacturer’s manual and replace if needed |
| Oil bath air cleaner: air inlet screen restricted / dirty air cleaner | Repair air inlet screen |
| Oil bath air cleaner: oil pull-over / oil viscocity too low or high | Replace lubricating oil with correct grade |
| Boost control malfunction: wastegate | Inspect for damage, leaks or obstructions; replace or repair if needed |
| Boost control malfunction: VNT | Contact us right away |
| Boost control malfunction: engine management system | Refer to engine manufacturer’s manual and adjust as needed |
| Possible Cause | Solution |
| Dirty air cleaner element | Clean or replaced filter element |
| Air cleaner element missing, leaking or loose connections to turbo | Replace, repair or reconnect air cleaner element per manufacturer’s manual |
| Collapsed or restricted air pipe before turbocharger | Inspect pipe for damage or obstructions, replace or repair |
| Restricted or damaged crossover pipe turbo to inlet manifold | Inspect pipe for damage or obstructions, replace or repair |
| Foreign object between cleaner and turbocharger | Inspect air intake piping, remove foreign object |
| Foreign object in exhaust system (from engine, check engine) | Inspect exhaust piping ONLY when engine is NOT running and cold, remove foreign object |
| Turbocharger flanges, clamp or bolt loose | Inspect all connecting hardware for damage, ensure tight fits per installation instructions |
| Inlet manifold cracked, gaskets loose or missing, connections loose | Remove and inspect inlet manifold for damage to castings and gaskets, replace if needed |
| Exhaust manifold cracked, burned, gasket loose, blown or missing | Remove exhaust manifold ONLY when engine is cold and NOT running and inspect for damage to castings and gaskets, replace if needed |
| Restricted exhaust system | Inspect exhaust system ONLY when engine is cold, NOT running, remove obstruction |
| Turbine housing damaged or restricted | Remove turbine housing, inspect for cracks or wear, replace if needed |
| Worn jounal bearing | Contact the number on the front of this brochure |
| Excessive dirt build-up behind turbine wheel | Inspect air cleaner element and intake piping for damage or leaks, replace if needed. Clean compressor wheel and housing |
| Excessive carbon build-up behind turbine wheel | Inspect crankcase ventilation system |
| Oil bath air cleaner: air inlet screen restricted / dirty air cleaner | Repair air inlet screen |
| Oil bath air cleaner: oil pull-over / oil viscocity too low or high | Replace lubricating oil with correct grade |
| Boost control malfunction: wastegate | Inspect for damage, leaks or obstructions; replace or repair if needed |
| Boost control malfunction: VNT | Contact us right away |
| Boost control malfunction: engine management system | Refer to engine manufacturer’s manual and adjust as needed |
| Possible Cause | Solution |
| Dirty air cleaner element | Clean or replaced filter element |
| Plugged crankcase breathers | Clear obstruction per manufacturer’s manual |
| Collapsed or restricted air pipe before turbocharger | Inspect pipe for damage or obstructions, replace or repair |
| Restricted or damaged crossover pipe turbo to inlet manifold | Inspect pipe for damage or obstructions, replace or repair |
| Foreign object between cleaner and turbocharger | Inspect air intake piping, remove foreign object |
| Turbocharger flanges, clamp or bolt loose | Inspect all connecting hardware for damage, ensure tight fits per installation instructions |
| Inlet manifold cracked, gaskets loose or missing, connections loose | Remove and inspect inlet manifold for damage to castings and gaskets, replace if needed |
| Restricted oil feed line | Remove and inspect oil line, remove obstruction |
| Turbocharger seal leakage | Inspect for proper oil feed / drain line installation. Contact the number on the front of this brochure for a rebuild. |
| Worn jounal bearing | Contact the number on the front of this brochure |
| Excessive dirt build-up behind turbine wheel | Inspect air cleaner element and intake piping for damage or leaks, replace if needed. Clean compressor wheel and housing |
| Excessive engine idle | Refer to engine manufacturer’s manual and adjust as needed |
| Oil filter plugged | Refer to engine manufacturer’s manual and replace if needed |
| Boost control malfunction: wastegate | Inspect for damage, leaks or obstructions; replace or repair if needed |
| Boost control malfunction: VNT | Contact us right away |
| Boost control malfunction: engine management system | Refer to engine manufacturer’s manual and adjust as needed |
| Possible Cause | Solution |
| Plugged crankcase breathers | Clear obstruction per manufacturer’s manual |
| Foreign object in exhaust system (from engine, check engine) | Inspect exhaust piping ONLY when engine is NOT running and cold, remove foreign object |
| Turbocharger flanges, clamp or bolt loose | Inspect all connecting hardware for damage, ensure tight fits per installation instructions |
| Restricted oil feed line | Remove and inspect oil line, remove obstruction |
| Restricted oil drain line | Remove and inspect oil line, remove obstruction |
| Turbocharger seal leakage | Inspect for proper oil feed / drain line installation. Contact the number on the front of this brochure for a rebuild. |
| Worn jounal bearing | Contact the number on the front of this brochure |
| Excessive carbon build-up behind turbine wheel | Inspect crankcase ventilation system |
| Excessive engine pre-oil | Refer to engine manufacturer’s manual and adjust as needed |
| Excessive engine idle | Refer to engine manufacturer’s manual and adjust as needed |
| Coked or sludged center housing | Contact us right away |
| Oil filter plugged | Refer to engine manufacturer’s manual and replace if needed |
| Boost control malfunction: wastegate | Inspect for damage, leaks or obstructions; replace or repair if needed |
| Boost control malfunction: VNT | Contact us right away |
| Boost control malfunction: engine management system | Refer to engine manufacturer’s manual and adjust as needed |
| Possible Cause | Solution |
| Air cleaner element missing, leaking or loose connections to turbo | Replace, repair or reconnect air cleaner element per manufacturer’s manual |
| Foreign object between cleaner and turbocharger | Inspect air intake piping, remove foreign object |
| Foreign object in exhaust system (from engine, check engine) | Inspect exhaust piping ONLY when engine is NOT running and cold, remove foreign object |
| Turbocharger flanges, clamp or bolt loose | Inspect all connecting hardware for damage, ensure tight fits per installation instructions |
| Oil lag at start-up | Inspect lubrication system lines, filters, and oil for obstruction, remove obstruction |
| Insufficient lubrication | Inspect lubrication system lines, filters, and oil for obstruction, remove obstruction |
| Lubricating oil contaminated with dirt or other material | Replace all filters and lubricating oil with new per manufacturer’s manual |
| Improper lubricating oil type used | Replace lubricating oil with correct grade |
| Restricted oil feed line | Remove and inspect oil line, remove obstruction |
| Worn jounal bearing | Contact the number on the front of this brochure |
| Excessive dirt build-up behind turbine wheel | Inspect air cleaner element and intake piping for damage or leaks, replace if needed. Clean compressor wheel and housing |
| Excessive carbon build-up behind turbine wheel | Inspect crankcase ventilation system |
| Leaking oil feed line | Remove and inspect oil line, remove obstruction |
| Coked or sludged center housing | Contact us right away |
| Oil filter plugged | Refer to engine manufacturer’s manual and replace if needed |
| Possible Cause | Solution |
| Foreign object between cleaner and turbocharger | Inspect air intake piping, remove foreign object |
| Foreign object in exhaust system (from engine, check engine) | Inspect exhaust piping ONLY when engine is NOT running and cold, remove foreign object |
| Turbocharger flanges, clamp or bolt loose | Inspect all connecting hardware for damage, ensure tight fits per installation instructions |
| Oil lag at start-up | Inspect lubrication system lines, filters, and oil for obstruction, remove obstruction |
| Insufficient lubrication | Inspect lubrication system lines, filters, and oil for obstruction, remove obstruction |
| Lubricating oil contaminated with dirt or other material | Replace all filters and lubricating oil with new per manufacturer’s manual |
| Improper lubricating oil type used | Replace lubricating oil with correct grade |
| Restricted oil feed line | Remove and inspect oil line, remove obstruction |
| Worn jounal bearing | Contact the number on the front of this brochure |
| Too fast acceleration at initial start | Decrease acceleration at initial start |
| Too little warm-up time | Extend warm-up period |
| Leaking oil feed line | Remove and inspect oil line, remove obstruction |
| Oil pump malfunction | Refer to engine manufacturer’s manual and replace if needed |
| Oil filter plugged | Refer to engine manufacturer’s manual and replace if needed |
| Boost control malfunction: wastegate | Inspect for damage, leaks or obstructions; replace or repair if needed |
| Boost control malfunction: VNT | Contact us right away |
| Boost control malfunction: engine management system | Refer to engine manufacturer’s manual and adjust as needed |
| Possible Cause | Solution |
| Air cleaner element missing, leaking or loose connections to turbo | Replace, repair or reconnect air cleaner element per manufacturer’s manual |
| Foreign object between cleaner and turbocharger | Inspect air intake piping, remove foreign object |
| Turbocharger flanges, clamp or bolt loose | Inspect all connecting hardware for damage, ensure tight fits per installation instructions |
| Worn jounal bearing | Contact the number on the front of this brochure |
| Excessive dirt build-up behind turbine wheel | Inspect air cleaner element and intake piping for damage or leaks, replace if needed. Clean compressor wheel and housing |
| Too fast acceleration at initial start | Decrease acceleration at initial start |
| Too little warm-up time | Extend warm-up period |
| Oil filter plugged | Refer to engine manufacturer’s manual and replace if needed |
| Boost control malfunction: wastegate | Inspect for damage, leaks or obstructions; replace or repair if needed |
| Boost control malfunction: VNT | Contact us right away |
| Boost control malfunction: engine management system | Refer to engine manufacturer’s manual and adjust as needed |
| Possible Cause | Solution |
| Foreign object in exhaust system (from engine, check engine) | Inspect exhaust piping ONLY when engine is NOT running and cold, remove foreign object |
| Turbocharger flanges, clamp or bolt loose | Inspect all connecting hardware for damage, ensure tight fits per installation instructions |
| Turbine housing damaged or restricted | Remove turbine housing, inspect for cracks or wear, replace if needed |
| Worn jounal bearing | Contact the number on the front of this brochure |
| Excessive dirt build-up behind turbine wheel | Inspect air cleaner element and intake piping for damage or leaks, replace if needed. Clean compressor wheel and housing |
| Excessive carbon build-up behind turbine wheel | Inspect crankcase ventilation system |
| Coked or sludged center housing | Contact us right away |
| Oil filter plugged | Refer to engine manufacturer’s manual and replace if needed |
| Boost control malfunction: wastegate | Inspect for damage, leaks or obstructions; replace or repair if needed |
| Boost control malfunction: VNT | Contact us right away |
| Boost control malfunction: engine management system | Refer to engine manufacturer’s manual and adjust as needed |