The turbocharger requires lubrication given the high rotational speeds.  

High rotational speeds, generate a lot of heat so adequate oil flow and cooling are crucial factors in order to extend the life of the turbocharger. 

What are the most common causes for Turbocharger breakdowns?

Damage from foreign objects (often in suction)

• Engine fragments, such as pieces of valves, can hit the turbine wheel, but also poor air filter maintenance can allow particles (of sand, gravel, and other impurities) to enter the turbo by hitting the propellers of the compressor wheel. 
• Damage to the propellers resulting in unbalancing of the turbine  
• Generating vibrations that worsen over time, leading to severe damage and turbo failure. 
• Inspection of a turbine on-site, may not always be feasible so it is important to make sure that the engine is in good health and that the air filters are quality and in good condition, this will help prevent premature damage. 
• In case you have the opportunity to inspect the turbine ( by removing the intake sleeve ) you can quickly check its condition by moving the turbine up and down, the presence any excessive play and/or any chipping and marks on the turbine propellers are indications of a balancing problem  
• In these cases, overhaul or replacement of the turbocharger is highly recommended in order to prevent damage to other engine components. 

Sudden engine shutdown at high RPM and/or without a cooling down period 

It is important to turn off the engine when it is at idle by giving the turbocharger a chance to cool down for a few seconds ( 30 to 40 sec. )  

This short period allows the cooling system to dissipate heat from the turbine and complete assembly, preventing Temperatures > 900°C from persisting inside the turbocharger causing carbonization due to heat transfer. 

Improper warm-up of a turbocharged engine is also important, as excessive expansion rate with a cold engine can cause cracks in components due to thermal shock. Respecting engine warm-up and cool-down times are important aspects to consider to avoid premature damage. 

Overheating  

Turbocharged engines reach much higher temperatures than older naturally aspirated engines → + Power = + Heat. Excessive heat can cause rupture or deformation of the heat shield and turbine housing thus deforming the turbine itself or cause melting or carbonization of components. To avoid this, it is important to keep the engine compartment air passages clear with proper cleaning of the radiators and hood grilles 

Low level or lack of engine oil  

Due to the high rotational speeds of the turbine ( >100,000 rpm ) lack or shortage of lubrication oil, even for a fraction of a second, can cause serious and costly damage. 

• Non-compliance with engine oil change times
  A turbocharger is not a sealed system, oil can leak out of the bearing housing and thus, exhaust gases can enter the oil. If the engine oil is not changed frequently enough, combustion deposits from the exhaust can gradually accumulate in the oil, contaminating it by changing its viscosity. If this happens there is a reduction in oil flow within the turbocharger, which can lead to turbine blockage. 
• Lubrication circuit problems  
  The lubrication system should be checked for visible damage and/or obstruction. 
• Using the correct lubrication fittings  
  Ensure that the fittings of the lubrication circuit are correct for the turbocharger so as not to restrict the oil supply to the main body bearings 

Incorrect engine design  

Many turbochargers are prone (and therefore repeat offenders) to failure, this happens when the engine is not quite suitable for the application. This may be the case with engines that are too small on very heavy vehicles or the presence of small engines on which too much horsepower has been developed. This leads to excessive lubrication oil pressures that can cause turbine shaft failure. 

Indicator signs of a defective turbocharger

• Excessive consumption of engine oil  
  Can result from wear of turbo seals, which thus allow oil to pass into the intake system 
• Overconsumption of fuel
  The stoichiometric ratio ( air/fuel mixture) of turbocharged engines is very precise. If the turbocharger is not working properly, it can vary the ratio by bringing incorrect air flow.  This results in, worse combustion and higher fuel consumption. 
• Bluish smoke
  The bluish colour of the exhaust gas is an indicator of oil combustion. If the problem stems from the turbocharger, blue smoke will occur both at engine idle speed and during standard operation at work. 
• Engine oil leaks
  You may have oil leaks near the intercooler clamps which may depend on a long period of engine downtime, if however, the leaks do not cease during use it is advisable to check the condition of the turbocharger. 
• Excessive and/or prolonged turbocharger “whistle”
  The turbocharger, generating high flows of compressed air, can generate a “whistle” which, however, if constant or very high-pitched, is an indicator of a defect on the bearing assembly or turbine. Should this condition occur, it is advisable to check the condition of the turbocharger. 
• Loss of power
  Most of the power developed by a turbocharged engine comes from the turbocharger itself, if this is damaged there is a major loss of performance 

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