Turbos 45 www.aftermarketonline.net MAY 2026 The leading cause of turbocharger failure As turbocharger technology continues to evolve alongside modern engine platforms, insufficient lubrication remains a significant cause of failures seen in workshops and, according to turbocharger specialist Melett, should not be overlooked. The issue of insufficient lubrication is rarely isolated to the turbocharger itself but instead linked to oil supply problems elsewhere in the engine system. Tom Wright, Group Product Manager at Melett, explained: “The causes of insufficient lubrication can be missed during routine servicing. Poor oil filter maintenance, low oil levels in the sump, and the use of unsuitable oil grades all remain frequent contributors. In addition, incorrect or damaged oil inlet gaskets that restrict oil flow, carbon build-up within oil feed pipes, worn oil pumps, and blockages from siliconebased sealants on oil gaskets can significantly compromise oil delivery to the turbocharger.” Another critical and preventable issue is the failure to correctly prime a replacement turbocharger before installation. “Even a few seconds of turbo operation without oil can be enough to cause irreversible damage to the bearing system,” Tom warned. Preventing insufficient lubrication Preventing lubrication-related turbocharger failure starts with ensuring unrestricted, clean oil flow to the unit. Melett advises technicians to thoroughly inspect and replace oil feed pipes to remove carbon deposits or sludge. Using fresh oil and new filters that meet the engine manufacturer’s specifications is essential, as is avoiding the use of silicone sealants on oil system components. Correct operating procedures also play a vital role. Allowing the engine to warm up properly before heavy loads and observing appropriate cooldown periods at the end of a journey helps protect the turbocharger from insufficient lubrication and heatrelated oil degradation, particularly on modern downsized and high-boost engines. Before replacing a faulty turbo, garage workshops should ensure the root cause has been fully diagnosed. Although symptoms such as oil leaks, unusual turbo noise, or reduced performance can suggest lubrication issues, workshops may not always be able to identify the underlying problem – and this is where a specialist turbo repairer can provide invaluable support. Tom added: “Once a turbo is dismantled by a specialist, the signs of lubrication failure are often unmistakable. Excessive wear on thrust and journal bearings, discolouration, scoring, or material transfer on bearing surfaces all indicate that lubrication has been compromised.” He stressed the importance of pinpointing the cause: “Insufficient lubrication can destroy bearings in seconds. Replacing the turbo without fixing the oil supply issue almost guarantees the same failure will happen again.” Tom concluded: “Correct lubrication is fundamental to turbo life. By following proper installation procedures, adhering to service schedules and taking a preventative approach, technicians can significantly reduce the risk of repeat turbo failures – and specialist support can make all the difference when diagnosing the true cause.” If the cause of a turbo failure isn’t clear, Melett can work with trusted, independent turbo repair specialists who can quickly perform accurate inspections to pinpoint the root cause and prevent repeat failures. www.melett.com
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