Turbochargers are the most efficient and powerful component of an internal combustion engine. Lest the reader be unaware of the importance of turbos, it is worth noting that turbos are largely responsible for the incredible improvement in engine efficiency over the past 60 years, as well as the substantial increase in power delivery. However, just like any other mechanical component, turbos have a tendency to fail. Wear and tear over time will eventually lead to complete failure of the turbocharger.
What does it involve to recondition a turbo? Why is reconditioning done? How is it done? These questions and more will be answered in this comprehensive guide to turbo reconditioning.
What is Turbo Reconditioning?
Turbo reconditioning, also known as turbo rebuilding or turbo refurbishment, is one term that’s used to refer to the process of rebuilding used turbochargers. The term “reconditioning” is a popular term for this process in turbo speak, where the goal is to refurbish the used turbo to make it work like new. Turbo reconditioning, or rebuilding, involves stripping down a used turbo, inspecting the parts for wear and damage, cleaning them, replacing worn parts, and reassembling them.
Why is Turbo Reconditioning Necessary?
Additionally, after some time, turbochargers can also get the following problems because of high operating temperatures, oil contamination and general wear:
Bearing Wear: The problem was caused by the oil inside the turbo circulating unevenly, which led to parts rubbing together due to the increase in friction until they eventually failed.
2. Oil Contamination: Contaminated oil from combustion byproducts such as carbon deposits can make their way into the turbo. Carbon deposits can make the turbo inefficient and will also ultimately cause damage. 3. Inadequate Oil Flow: Without an adequate amount of oil to the turbo, insufficient lubrication will also result in damage. 4. Incorrect Oil Viscosity: Using the wrong viscosity of oil for the engine you have will result in excessive oil consumption that, if not burnt off, will eventually foam and cause damage to the turbo.
Compressor or Turbine Damage: Objects outside the air-intake, or excessive heat entering the engine, can damage the compressor and turbine blades.
Leaky seals: worn seals can cause oil leaks which reduces performance and can damage your engine.
This re-conditioning corrects these problems, so that the turbocharger can continue to produce the necessary performance without the cost of a new unit.
The Turbo Reconditioning Process
The process of reconditioning a turbocharger is meticulous and involves several key steps:
1. Disassembly
The initial stage of the reconditioning of a turbocharger involves disassembly in its entirety, starting from the unscrewing of the compressor housing, the turbine housing, as well as the central housing with the bearings and shaft. Every part is inspected for damages.
2. Cleaning
All the parts are removed, cleaned, and one by one, sprayed with chemical cleaners and put in ultrasonic cleaning baths to get rid of oil, carbon deposits and other grime.
3. Inspection and Measurement
After they’re clean, individual components are inspected for wear and damage. Critical dimensions are taken to ensure they are within the original manufacturer’s specs. The turbine shaft, the compressor wheel and bearings are inspected visually for any damage or wear.
4. Replacement of Worn Parts
Any parts below spec are replaced. Components that are commonly replaced are the bearings, seals and thrust collars. Replacement parts must be of the highest quality to prolong the life of your turbo and keep it running optimally.
5. Balancing
An essential part of most turbo reconditioning processes is balancing. The assembly (the turbine shaft and the compressor wheel) that rotates inside the turbo must be carefully balanced to prevent the vibrations that will eventually cause it to fail. To balance, the assembly is spun on special equipment at high rpm so that any imperfections in the assembly can be detected.
6. Reassembly
After that all the parts are washed, weighed and balanced, and the turbocharger unit is put back together. Old leaks are patched with new seals and gaskets.
7. Testing
The last stage is the test: once completely reconditioned, the component is fitted to a test bench where it can be run under controlled conditions and parameters including boost pressure, oil flow and rotational speed can be monitored to ensure that the turbo works to specification.
Benefits of Turbo Reconditioning
It is better to recondition a turbocharger than to buy a new one because: 1. It is less expensive 2. It takes less time 3. It is better for the environment 4. It is more reliable 5. It is easier to use When you recondition a turbocharger, you get to keep your old one. This saves you money. Saving time is another great advantage. If the turbocharger you receive is reconditioned, you don't need to return your vehicle to the dealer to have it installed. You can drive it home when it is finished. In addition to saving time and money, using the old part saves energy and resources, because a new turbocharger does not have to be produced from scratch. This is better for the environment, because pollution is reduced in the area where the part is produced. Furthermore, reconditioned parts tend to be the best possible quality, because they are checked and re-built by experts. When you buy a reconditioned turbocharger, you know you are getting the highest quality.
Cost Savings: Reconditioning is generally much more affordable than purchasing a new turbocharger.
Environmental Impact: Reconditioning reduces waste by extending the life of existing components.
Performance: For example, once remanufactured correctly, the turbocharger’s performance will be the same, or better, than that of a new turbo, thereby bringing the car back to its original, manufacturer power and efficiency.
Conclusion
If you have a worn-out turbo left, this process can make your turbo look like a new one. If you own a turbocharged vehicle, now you have a better understanding about turbo reconditioning process and its advantages. Whether you want to save your money, have a lower impact on the environment or just make your vehicle perform better, turbo reconditioning is definitely a way to go.
So let your rebuilt turbo work overtime and your engine will keep on running.
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