When it comes to turbo failure, few things are as destructive—or as avoidable—as foreign object damage (FOD). Whether you're building boost on the street or the track, even the smallest debris can turn your turbo into expensive scrap.
At Demon Pro, we’ve seen it all—from tiny screws sucked into the intake to snapped blades from a forgotten washer. Here's what you need to know to protect your investment.
What is Foreign Object Damage (FOD)?
Foreign object damage occurs when debris enters either side of the turbocharger—intake or exhaust—and collides with the rotating turbine or compressor wheels. This damage happens fast, and it’s often catastrophic.
Common culprits include:
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Loose bolts, washers, or gasket material
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Damaged or degraded air filters
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Bits of a broken engine component
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Intake or intercooler fragments
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Metal shards from a previous turbo failure
Signs You’ve Suffered FOD
If you’ve experienced FOD, it usually doesn’t go unnoticed. Some telltale signs include:
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Chipped or bent blades on the compressor or turbine
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Imbalance noise (whistling, rattling, or screeching)
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Excessive vibration
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Oil leaks from damaged shaft seals
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Boost pressure drops or no boost at all
Real-World Consequences
Damage from even a small object can cause:
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Immediate performance loss
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Complete turbo failure
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Engine damage if fragments pass through
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Warranty voids (because FOD is avoidable!)
At Demon Pro, we inspect all returned turbos, and foreign object damage is one of the most common reasons we cannot process a warranty claim. It's easy to prevent—but once it's done, there’s no quick fix.
How to Prevent It Like a Pro
Want your turbo to live a long, powerful life? Follow these FOD-prevention best practices:
✅ Inspect Before Install
Before fitting a new turbo, always clean out the intake piping, intercooler, and air filter. One tiny leftover bolt can destroy your setup.
✅ Use a Quality Air Filter
Cheap filters let dirt through. Use a reputable, high-flow filter and inspect it regularly for wear or gaps.
✅ Secure Your Hardware
Loose bolts, intake clamps, or broken airboxes are red flags. Tighten everything up before turning the key.
✅ Post-Failure Cleanout
Replacing a blown turbo? Thoroughly clean the entire system—intake to exhaust. If metal from the failed unit is still inside, your new turbo is at serious risk.
What to Do If It Happens
If you suspect foreign object damage, stop the engine immediately. Continuing to drive can cause more serious (and expensive) damage. Pull the intake pipe and inspect the compressor wheel. If it’s damaged, don’t run the engine again until it’s repaired or replaced.
