Ihi Turbo Repair Manual

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Ihi Turbo Repair Manual

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Bearings scored from lack of oil supply or bad oil / contamination
Bearing failure
Scored bearing on turbine wheel. See shaft is blue from getting hot from lack of oil lubrication
Cracked turbine housing at exhaust inlet
Cracks in trubine housing inside housing
Internal turbine housing cracks
Ihi Turbo Repair Manual PdfBurst compressor wheel
Foreign object damage to compressor wheel
Ihi Turbo Japan

Compressor wheel failure after scrubbing walls of compressor cover, secondary failure after bearings have failed
Exhaust bypass cracks
Ihi Turbo UsaCompressor wheel scrubbing compressor cover
Foreign object damage on compressor inlet
Foreign object damage on compressor inlet

Thrust bearing stack up
Ihi Turbo Repair Manual TransmissionExample of thrust bearing cracks and damage
Thrust bearing scoring and damage
Ihi Turbos For SalePiston ring damage and bearing journal damage from lack of proper oil supply
Broken turbine wheel and shaft from abrupt stop

Bearings scored from lack of oil supply or bad oil / contamination
Bearing failure
Scored bearing on turbine wheel. See shaft is blue from getting hot from lack of oil lubrication
Cracked turbine housing at exhaust inlet
Cracks in trubine housing inside housing
Internal turbine housing cracks
Ihi Turbo Repair Manual PdfBurst compressor wheel
Foreign object damage to compressor wheel
Ihi Turbo JapanCompressor wheel failure after scrubbing walls of compressor cover, secondary failure after bearings have failed
Exhaust bypass cracks
Ihi Turbo UsaCompressor wheel scrubbing compressor cover
Foreign object damage on compressor inlet
Foreign object damage on compressor inlet
Thrust bearing stack up
Ihi Turbo Repair Manual TransmissionExample of thrust bearing cracks and damage
Thrust bearing scoring and damage
Ihi Turbos For SalePiston ring damage and bearing journal damage from lack of proper oil supply
Broken turbine wheel and shaft from abrupt stop
Broken turbine wheel blade from foreign object damage, most likely from an engine valve or piston
Foreign object damage from engine
Damage to turbine wheel from scrubbing turbine housing
Vanes on variable vane geometry turbo
Damage to vanes on variable vane geometry turbo
Ihi Turbo AmericaTurbocharger air flow diagram
Ihi Turbo Repair Manual SoftwarePossible Failure DiagnosisEngine Running HotPoor Transient ResponseSmokeEngine Lacks PowerBlack Exhaust SmokeBlue Exhaust SmokeHigh Oil ConsumptionTurbocharger NoisyCyclic Sound from the TurbochargerOil Leak from Compressor SealOil Leak from Turbine Seal
Dirty air cleaner
Clean or replace element according to manufacturer's recommendations
Restricted compressor intake duct
Remove restriction or replace damaged parts as required
Restricted air duct from compressor to intake manifold
Replace seals, gaskets or tighten fasteners as required
Restricted intake manifold
Refer to engine manufacturer's manual and remove restriction
Air leak in feed from air cleaner to compressor
Replace seals, gaskets or tighten fasteners as required
Air leak in feed from compressor to intake manifold
Replace seals, gaskets or tighten fasteners as required
Air leak between intake manifold and engine
Refer to engine manufacturer's manual and replace gaskets or tighten fasteners as required
Foreign object in exhaust manifold (from engine)
Refer to engine manufacturer's manual and remove obstruction
Restricted exhaust system
Remove restriction or replace damaged parts as required
Exhaust manifold cracked, gaskets blown or missing
Refer to engine manufacturer's manual and replace gaskets or damaged parts as required
Gas leak at turbine inlet/exhaust manifold joint
Replace gasket or tighten fasteners as required
Gas leak in ducting after turbine outlet
Refer to engine manufacturer's manual and repair leak
Restricted turbocharger oil drain line
Remove restriction or replace damaged parts as required
Restricted engine crankcase breather
Refer to engine manufacturer's manual, clear restriction
Turbocharger bearing housing sludged or coked
Change engine oil and oil filter, overhaul or replace turbocharger as required
Fuel injection pump or fuel injectors incorrectly set
Refer to engine manufacturer's manual and replace or adjust faulty components as required
Engine valve timing incorrect
Refer to engine manufacturer's manual for correct settings and adjust as required
Worn engine piston rings or liners
Refer to engine manufacturer's manual and repair as required
Burnt valves and/or pistons
Refer to engine manufacturer's manual and repair as required
Excessive dirt build-up on impeller and/or diffuser vanes
Clean in accordance with the appropriate manufacturer repair manual
Turbocharger damaged
Find and correct cause of failure, repair or replace turbocharger as necessary
Failed diaphragm
Replace using correct Actuator Service Kit
Siezed valve
Free valve/replace complete turbine housing sub-assembly
Leaking hose
Replace hose and clips
Wastegate mechanism set incorrectly

Possible Failure Diagnosis	Engine Running Hot	Poor Transient Response	Smoke	Engine Lacks Power	Black Exhaust Smoke	Blue Exhaust Smoke	High Oil Consumption	Turbocharger Noisy	Cyclic Sound from the Turbocharger	Oil Leak from Compressor Seal	Oil Leak from Turbine Seal
Dirty air cleaner Clean or replace element according to manufacturer's recommendations
Restricted compressor intake duct Remove restriction or replace damaged parts as required
Restricted air duct from compressor to intake manifold Replace seals, gaskets or tighten fasteners as required
Restricted intake manifold Refer to engine manufacturer's manual and remove restriction
Air leak in feed from air cleaner to compressor Replace seals, gaskets or tighten fasteners as required
Air leak in feed from compressor to intake manifold Replace seals, gaskets or tighten fasteners as required
Air leak between intake manifold and engine Refer to engine manufacturer's manual and replace gaskets or tighten fasteners as required
Foreign object in exhaust manifold (from engine) Refer to engine manufacturer's manual and remove obstruction
Restricted exhaust system Remove restriction or replace damaged parts as required
Exhaust manifold cracked, gaskets blown or missing Refer to engine manufacturer's manual and replace gaskets or damaged parts as required
Gas leak at turbine inlet/exhaust manifold joint Replace gasket or tighten fasteners as required
Gas leak in ducting after turbine outlet Refer to engine manufacturer's manual and repair leak
Restricted turbocharger oil drain line Remove restriction or replace damaged parts as required
Restricted engine crankcase breather Refer to engine manufacturer's manual, clear restriction
Turbocharger bearing housing sludged or coked Change engine oil and oil filter, overhaul or replace turbocharger as required
Fuel injection pump or fuel injectors incorrectly set Refer to engine manufacturer's manual and replace or adjust faulty components as required
Engine valve timing incorrect Refer to engine manufacturer's manual for correct settings and adjust as required
Worn engine piston rings or liners Refer to engine manufacturer's manual and repair as required
Burnt valves and/or pistons Refer to engine manufacturer's manual and repair as required
Excessive dirt build-up on impeller and/or diffuser vanes Clean in accordance with the appropriate manufacturer repair manual
Turbocharger damaged Find and correct cause of failure, repair or replace turbocharger as necessary
Failed diaphragm Replace using correct Actuator Service Kit
Siezed valve Free valve/replace complete turbine housing sub-assembly
Leaking hose Replace hose and clips
Wastegate mechanism set incorrectly