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We offer regeneration of turbochargers used in the engines of cars, vans and trucks, buses and commercial vehicles and machinery. The range includes turbochargers from all leading manufacturers such as Garrett, BorgWarner Turbo Systems (KKK and Schwitzer), Mitsubishi, IHI, Continental, Bosch Mahle Turbo Systems, Holset. We regenerate both wastegate and variable geometry turbochargers (VNT/VGT/VTG), as well as biturbo and twinturbo systems. In the process repair of turbochargers we use state-of-the-art equipment and technology as well as spare parts of the highest quality. The high quality is backed up by a 24-month unlimited mileage warranty.

Turbocharger - genesis and application.

Since their invention, turbochargers have changed the face of motoring and industry. Initially used mainly in aviation, they quickly found their way into passenger cars, trucks and the marine and aerospace industries. Thanks to their ability to increase engine power while reducing exhaust emissions, they have become an integral part of many modern vehicles. Initially, turbochargers faced some problems, such as a delay in response to changes in engine load (known as turbo lag/turbo lag) and higher lubrication and cooling requirements. However, thanks to advances in technology and the introduction of advanced control systems, these problems have largely been solved. Sufficiently fast and precise regulation of boost pressure, and thus harmonious development of engine power and high torque values, is possible thanks to the introduction of variable turbine geometry, electronic actuators and Twin Turbo designs, i.e. sequential charging. Regular turbocharger cleaning further maintains its efficiency and prevents failures.

Construction and principle of operation.

The exhaust gases leaving the engine cylinders are directed through an exhaust manifold into the turbine housing. Flowing through the turbine blades located there, they set the turbine in motion. turbocharger rotor After which they escape freely into the engine's exhaust system. At the other end of the shaft is the compressor, in which the rotating compressor wheel (compression wheel) draws in air, compresses it to a pressure higher than atmospheric pressure and directs it further through the intake pipes to the engine cylinders. A regulating system is responsible for adjusting and maintaining the correct pressure value. wastegate or variable turbine geometry (VNT/VGT/VTG) system. The rotating system is supported in the turbocharger's midbody by plain bearings (less commonly ball bearings): main and axial (thrust). The engine oil is continuously supplied under pressure to the turbocharger's midbody (bearing housing/core/corax), flows through the bearing arrangement of the rotating system and then flows freely back to the engine. Some models of turbochargers have additional channels in the bearing housings through which coolant flows - to improve turbocharger core cooling and reducing the risk of oil sintering inside it.

Construction of the turbocharger:

1. Turbine housing (so-called heat side)
2. Impeller with turbine wheel
3. Bearing housing (core/CHRA)
4. Bearing - main and axial bearing(s)
5. Sealing rings and other seals
6. Compressor housing (so-colled cold side)
7. Compressor wheel (compression wheel)
8. Charge pressure control system (wastegate or variable geometry)
9. Boost pressure actuator (pressure/vacuum valve or electronic adjuster)
10. Compressed air bypass valve (petrol engine turbochargers only)

Exhaust gas leaving the engine's cylinders drives the turbine, which in turn compresses the air and directs it into the cylinders, increasing the unit's power output. Regular maintenance and turbocharger regeneration keeps the process fully efficient, and adequate lubrication and core cooling prevents failures.

Turbo regeneration step by step

Professional turbocharger regeneration takes place in several stages:

1. Preliminary technical assessment - mainly to assess the presence and location of oil leaks, visible mechanical damage, evaluation of the operation of the boost pressure control system, efficiency of the valve/valves and electronic adjusters.
2. Disassembling the turbocharger into its component parts - allows access to individual parts of the turbocharger and a thorough assessment of all components.
3. Cleaning of components - Sometimes it is only after thorough cleaning that they can be accurately verified. Some components after turbocharger cleaning will be reused in the reconditioning process (provided they are not damaged).
4. Completion of new items - parts to replace damaged parts or those that are always being replaced (bearings, seals).
5. Thorough test of the valve/pressure regulator or electronic adjuster - at this stage, the position sensor of the variable geometry system or bleed valve (if present and damaged) is replaced and the electronic adjuster of the bleed/variable geometry valve (if damaged) is regenerated.
6. Slow balancing of the turbocharger rotor - the first of two stages of balancing a turbocharger's rotating system, consisting in correcting the "run-out" of the rotor during operation. The measurements are carried out on a high-quality Schenck balancing machine.
7. Assembling the turbocharger core - The complete rotating system with new bearings and seals is mounted in the turbocharger's centre body ("core", "CHRA").
8. High-speed balancing of the rotating system - accurate measurement and correction of the balance of a complete rotating system operating in a bearing arrangement at speeds of up to 200,000 revolutions per minute. Over several measuring cycles, the unbalance is corrected to the correct value, often lower than the brand new turbochargers. During this operation, the turbocharger operates under similar conditions to an internal combustion engine - the rotating system reaches speeds of the order of 200,000 rpm, and engine oil is continuously supplied to its bearings at the appropriate pressure (which also makes it possible to verify the tightness of the turbocharger's lubrication system). The high-speed balancing process is carried out on high-quality Schenck balancing machines.
9. Preassembly of turbocharger and setting/calibration of the boost pressure control system - fine adjustment of the operating range of the bleed valve or variable geometry system.
10. Final turbocharger assembly and final quality control in accordance with ISO 9001:2015.

Causes and types of damage.

With our specialists, you can be sure that repair of turbochargers is carried out in a comprehensive and professional manner. Our aim is not only to rectify the fault, but also to understand and provide the customer with information on possible causes. We believe that this approach will help to avoid similar problems in the future, so we always strive to act transparently and with full commitment.

Symptoms that may indicate a defective turbocharger:

1. Deterioration of engine performance (often referred to as "lack of engine power")
2. Noise - whistling, humming
3. Grey/blue/black smoke coming from the exhaust pipe
4. Turbocharger oil leaks, increased engine oil loss

Repair of turbochargers - the most common damages are:

1. Oil leaks into the engine intake and/or exhaust system usually caused by damage or working out of the turbocharger's sealing rings or an increase in rotor clearance. It should be noted, however, that oil leaks can also affect a fully operational turbocharger that does not have the right operating conditions (primarily free flow of oil from the turbocharger to the engine).
2. Mechanical damage to compressor and/or turbine blades caused mainly by foreign bodies in the engine intake or exhaust system.
3. Increased radial and/or axial rotor clearance (in extreme cases, a broken shaft) usually resulting from contamination of the engine oil or lack of adequate lubrication of the rotating system.
4. Defects in the boost pressure control system - Leakage or blockage of the pressure/vacuum valve, damage to the turbo copy sensor (bleed or variable geometry valve position sensor), electronic adjuster. Too much carbon build-up can block or limit the operating range of the turbo variable geometry system.
5. Cracks in the turbine housing (including the engine exhaust manifold if integrated with it). The phenomenon is particularly common in turbochargers operating in petrol engines due to the higher exhaust gas temperature compared to a diesel engine.

In such cases, rapid turbocharger repairpreferably from specialists with the appropriate technical background. Sometimes professional turbocharger cleaning, in other situations full turbo regenerationto restore it to full capacity.

Turbo reconditioning - why choose our services?

With us, you can be sure that turbocharger regeneration is carried out to the highest quality and safety standards. We use modern diagnostic equipment, special balancing machines and original or certified spare parts, which guarantees the reliability and long service life of repaired components. Our approach is comprehensive - We do not limit ourselves to rectifying the fault, but always analyse the cause of the failure in order to effectively prevent it from recurring in the future.

If you care about turbo regeneration was carried out quickly, reliably and with guaranteed quality, choosing our services is the best decision. Your turbocharger will regain full efficiency and be ready for long, trouble-free operation.