Turbochargers are critical for the operation of many of today’s automobiles, especially high-performance vehicles and diesel engines. Turbochargers function by directing exhaust gas to burn new fuel, which is forced into the engine to create more power and improve mileage by increasing the volume of air being compressed and burned. Because running a turbocharger generates so much heat in such a compact space, over time it can cause a build-up of muck that changes the mechanics of the moving parts, causing them to wear down and eventually cease to function properly. When this happens, there’s usually a sudden and severe decrease in vehicle performance that would result in an urgent need for repair or a replacement.
If the cost of a new turbo is prohibitive, turbo refurbishment may be the most financially appropriate and eco-friendly decision for your vehicle. What is turbo rebuilding? • Why is turbo refurb good for the environment? • How is a turbo refurbished? • When is turbo refurb the best option for your vehicle? Read on to find out who does your turbo rebuild, and why should you choose a company with more than just experience.
What is Turbo Refurbishment?
Turbo refurbishment involves rebuilding a used or damaged turbocharger to make it work as it did when new. By inspecting the turbocharger for damage, replacing parts as necessary, washing the components and fitting them together, you can start turning your engine as if you had purchased a brand new turbo. This will extend the life of your turbo and shouldn’t cost nearly as much as a new turbocharger.
These turbos will be refurbished, from humble mainstream passenger vehicle turbos to exotic race car and heavy-duty diesel turbochargers.
The Turbo Refurbishment Process:
Turbo refurbishment generally consists of multiple stages where the level of functionality is significantly upgraded over time resulting in a ‘like new’ turbocharger.
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Turbo refurbishment generally consists of multiple stages where the level of functionality is significantly upgraded over time resulting in a ‘like new’ turbocharger.
The first stage includes a thorough examination of the turbocharger’s internal components followed by a blasting of the internal cavities with steel or glass beads which effectively removes the oldest debris and flakes. Next, the turbocharger is horizontally mounted and spun to remove any remaining internal debris. Subsequently, additional dirt is addressed by treating the unit with steam and performing an internal paint coating which comes in various color options.
The second stage encompasses an internal mechanical recycling of worn components. These parts undergo a process where they are rotated and fixed with adhesive before undergoing an oven baking process to achieve the required strength.
The third stage entails the complete dismantling of the main components and brakes which are custom fitted in 6 angular groves that dimple the surface. Any thermal degradation of the ambient air inlet is eradicated with a circular sanding process. The fourth stage involves the respraying of the entire component in a variety of vibrant colors.
1. Initial Inspection
The process will start from an inspection examination of the turbocharger. The turbo will be dissembling as reactions attached above on the main body, inside of the auxiliary section. Then the technicians can inspect the turbine, compressor wheel, bearings and seals. They will act and record the presence of grinding, pick up signs which will suggest that area of the turboheads are worn out, showing cracks or signs that its lection are result in direct contact with high temperature and excessive pressure cause external power source and secondary explosions.
2. Disassembly
Then the fully checked instructive stage will be dismantled the turbocharger. Every part (turbine and compressor wheels, bearings, housings etc) are divided from each other and examined, or cleaned up.
3. Cleaning
Occasionally by-products of combustion of carbon deposits, oil residue and other deposits hamper turbocharger performance while the engine is on the road. Therefore, internal and external parts are cleaned from this soiling and the turbocharger is ready for using again after reconvention. Costumers are already aware that the performance just after refurbishment is much better. Pretty special liqid which is generating high pressure is used for entire disassembly during cleaning process. Where some parts are so thin than human hair a simple chemical cleaning could be not enough.
4. Component Replacement
By which we mean that worn-out or damaged parts such as seals, bars, gaskets, turbine wheels, compressor wheels, etc are replaced with factory-new, good-as-new replacement parts.
5. Reassembly and Balancing
The turbocharger is carefully cleaned and recycled parts replaced, then reassembled. Machining is carried out to balance the rotating assembly of the turbo to a specific tolerance, minimizing vibrations to an acceptable level precluding further damage and stress on the engine.
6. Testing
At this point the turbo is fully rebuilt and it needs to go through testing again. This ensures that the turbine and compressor still perform to specifications, particularly in terms of making sure the turbo assembly is leak-free, that there is an appropriate boost described as the amount of pressure in the intake manifold, and finally that the turbo is not making any noise or vibrations. If a turbo passes through all these tests, it fits to say the turbo is now fully rebuilt and ready to return to service.
Benefits of Turbo Refurbishment
The major advantages of turbo refurbishment make it clear why it’s a good alternative to investing in a new turbocharger.
1. Cost Savings
The main benefits of turbo refurbishment is the money you save. Brand new turbochargers aren’t cheap especially on high performance vehicles, rebuilding your existing one is usually far less expensive because most of the original components are reused and only the parts worn or damaged are replaced this can save alot of money for vehicle owners.
2. Restored Performance
A properly rebuilt turbo will get your car back to performing just like a new turbo, especially since worn parts and contaminated components are replaced, allowing the power, efficiency and acceleration loss of a failing turbo to be recovered, often undetectable to the driver. It’s really not such a crazy or wild dream to say that you can get your car back to performing like a new car.
3. Environmentally Friendly
Turbo outer refurbishment is also more green than buying a new unit – recycling an existing turbo unit requires less raw materials to be used and less energy to be expended than manufacturing new turbochargers. This in turn means less turbo units finding themselves in land fill, and less turbocharger life cycle impact on the environment.
4. Faster Turnaround
In many instances, turbo refurbishment may actually be performed faster than sourcing and installing a compatible replacement turbo. Depending on OEM availability of replacement parts, the refurbishment process may in fact only take a couple of days, getting your vehicle back out on the road much faster.
When Should You Consider Turbo Refurbishment?
To ensure you correct a failing turbo before it does further damage and costly repairs, here are the most commonly experienced indications that your turbo may require refurbishment:
Loss of Power: Your car’s not turbocharging as well as it once did? Chances are good that your turbo is on the fritz.
Excessive Smoke: If the exhaust is billowing blue (or occasionally black) smoke, it can indicate that oil is leaking into the turbo system, which can mean internal damage.
Strange Sounds: An unusually loud whine or whistle coming from the turbo region could indicate worn bearings or some other internal problem.
Sudden Increase in Oil Consumption: The most common reason for consuming oil rapidly is leaking turbo seals, a sign that a turbo is close to failure.
Conclusion
Turbo refurbishment is the most cost-effective way of bringing your turbocharger back to life so you can maintain economy and continued motive power at a very affordable price. It is much more economically advantageous to get the unit refurbished than buying a brand new one, and this option is better for the environment as well. If your vehicle is experiencing any of the telltale symptoms of a failing turbo, turbo refurbishment can help you increase the longevity of the unit, with the end goal of keeping your motor long-lasting and economy on the road even after a failure. Whether you’re looking to boost performance and speed or enhance fuel efficiency, there’s a turbo refurb option that can achieve that for you.
Turbo Refurbishment: A Practical and Sustainable Solution for Turbocharger Maintenance