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Overhauled turbochargers

If a turbocharger needs to be overhauled, he is first given a general check. This includes the search for mechanical damages as well as for oil in the housing. In addition to that, the wave and the function of the boost pressure control are checked.

In a second step the turbocharger is then dismantled. Since mechanical damages and signs of wear often only then become visible, a second, more detailed check of the components follows. Consumable parts, like axial and radial bearings or seals are disposed of properly and replaced by new components.

The next step of the general overhaul includes a thorough cleaning of all components in several steps: Except for the charge-air pressure control systems and the electrical solenoid valves all components pass through a basic cleaning and 20 bar of pressure in the hot car-wash with 80 degrees centigrade of a warm water.

After this first basic cleaning, components made of steel and aluminum need even further cleaning steps in special machines. Possible residues of the cleaning agent used there are then removed by means of compressed air, then a second basic cleaning follows.

Only then the individual components are ready for a post-processing. Threaded holes are trimmed and different places of the bearing housing are polished. A final cleaning by means of compressed air and a flush completes this step.

The repeated cleaning procedures undoubtedly require a lot of effort, but there isn't any alternative to this. To make the later assembly proceed without any interference and to ensure the functionality of the turbocharger, all components must be a hundred per cent free from foreign substances and residue cleaning agent. The multi-stage cleaner procedures are therefore an essential component of the professional overhaul of a turbocharger.

Following the cleaning procedures, the qualities of the individual components are checked and coordinated with the manufacturer specifications and quality standards. If deviations should arise according to these, the corresponding component is either reworked or, if this is no longer possible, replaced. Moreover, single components get an anti-corrosion protection.

With this step, the overhaul of the turbocharger is nearly finished: All the cleaned, reworked or replaced components cleaned are now professionally put together again.

The precise balancing in two steps follows: First, the wave is balanced, then the complete system. In the second step of the balancing the turbocharger needs to achieve about 300,000 revolutions per minute - this corresponds to the speed of the running engine. The simultaneous injection of engine oil serves to check the turbocharger for permeability.

The last step is the calibration of the settings of the charging pressure by means of modern measuring instruments. After this, the completely overhauled turbocharger is ready for the assembly.

If a turbocharger needs to be overhauled, he is first given a general check. This includes the search for mechanical damages as well as for oil in the housing. In addition to that, the wave and... read more »
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Overhauled turbochargers

If a turbocharger needs to be overhauled, he is first given a general check. This includes the search for mechanical damages as well as for oil in the housing. In addition to that, the wave and the function of the boost pressure control are checked.

In a second step the turbocharger is then dismantled. Since mechanical damages and signs of wear often only then become visible, a second, more detailed check of the components follows. Consumable parts, like axial and radial bearings or seals are disposed of properly and replaced by new components.

The next step of the general overhaul includes a thorough cleaning of all components in several steps: Except for the charge-air pressure control systems and the electrical solenoid valves all components pass through a basic cleaning and 20 bar of pressure in the hot car-wash with 80 degrees centigrade of a warm water.

After this first basic cleaning, components made of steel and aluminum need even further cleaning steps in special machines. Possible residues of the cleaning agent used there are then removed by means of compressed air, then a second basic cleaning follows.

Only then the individual components are ready for a post-processing. Threaded holes are trimmed and different places of the bearing housing are polished. A final cleaning by means of compressed air and a flush completes this step.

The repeated cleaning procedures undoubtedly require a lot of effort, but there isn't any alternative to this. To make the later assembly proceed without any interference and to ensure the functionality of the turbocharger, all components must be a hundred per cent free from foreign substances and residue cleaning agent. The multi-stage cleaner procedures are therefore an essential component of the professional overhaul of a turbocharger.

Following the cleaning procedures, the qualities of the individual components are checked and coordinated with the manufacturer specifications and quality standards. If deviations should arise according to these, the corresponding component is either reworked or, if this is no longer possible, replaced. Moreover, single components get an anti-corrosion protection.

With this step, the overhaul of the turbocharger is nearly finished: All the cleaned, reworked or replaced components cleaned are now professionally put together again.

The precise balancing in two steps follows: First, the wave is balanced, then the complete system. In the second step of the balancing the turbocharger needs to achieve about 300,000 revolutions per minute - this corresponds to the speed of the running engine. The simultaneous injection of engine oil serves to check the turbocharger for permeability.

The last step is the calibration of the settings of the charging pressure by means of modern measuring instruments. After this, the completely overhauled turbocharger is ready for the assembly.

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