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PSEP offer a comprehensive high quality remanufacturing service for your failed/failing Turbo. We have extensive knowledge of BorgWarner, Garratt, Hitachi, Holset, IHI, Mitsubishi, Schwitzer and Toyota turbos plus many more.
If serviceable, rebuilding your old Turbo can save you a significant amount of money compared to buying a new unit outright. Remanufacturing of you old Turbo will bring it back to factory standard or better and suitable for all Agricultural, Commercial, Industrial, Off-Highway, Power Generation and Marine applications. All remanufactured Turbos are supplied with a 12 month warranty.
We will organise the collection of your Turbo and then a full inspection will be carried out and you will be provided with the details of the work required and cost of remanufacturing. Below is a list of the steps within the remanufacturing process:
- Disassemble
- Clean
- Test Vacuum / Electronic Actuator
- Oil Pressure Test
- Fit Rebuild Kit, compressor wheel and turbine wheel
- Rotating assembly balance
- Reassembly CHRA
- VSR Balance CHRA
- Assemble Turbocharger
A turbocharger is a key component of the engine and is designed and manufactured to last the life of the engine with proper preventative maintenance, it is not to say that turbos don’t fail. When they do, 90% of the time the failure can be diagnosed as the turbocharger ingesting a foreign object or due to poor maintenance. Foreign objects will damage, if not destroy a turbocharger, it is paramount that the air filters are changed faithfully in line with the engine manufacturers recommendations. Changing filters has the added benefit of preventing excessive drop in air pressure across the filter and a vacuum at the turbochargers compressor oil seal which in the long term will damage the seal.
Another general tip for extended turbocharger life is to let an engine idle for a minute or so after hard running, this allows the turbocharger slow down while cooling down, use of this old tried and trusted procedure will result in extended turbo life.
Troubleshooting Turbocharger Faults
The most common engine symptoms related to lack of turbocharger performance are:
- Loss of Engine Power
- Excessive Black Exhaust Smoke
- Excessive Blue Exhaust Smoke
- Excessive Oil Consumption
- Oil in Exhaust manifold
- Turbocharger Noisy
- Ingestion of coolant from a water cooled bearing
When dealing with lack of power, first determine if the engine is operating correctly, if the engine runs well, then there is an excellent chance that the fault is in the turbocharger system.
In determining what’s making the turbocharger perform badly, check all inlet connection for an airtight fit from the turbocharger to the engine, loose hoses clamps or faulty hoses will let boost escape. During the examination of the turbo look for tell-tale signs of an exhaust leak upstream from the turbine housing back to the engine. Any exhaust leaks will limit the turbo performance since not all exhaust gas is flowing into the turbocharger’s turbine this in turn degrades its ability to compress the combustion air. When looking at the system be sure to check the integrity of the turbocharger’s intercooler, a common fault is to get a crack in a tank or a small pin hole in a tube, trucks are particularly susceptible to this. If the oil seal in the turbo’s compressor fails, it will force lubricant into the charge air cooler, wash the lubricant out since it will not only cause excessive exhaust smoke but will severely limit the thermal conductivity of the unit.
Stuck Wastegate
On a turbocharger with a wastegate device you need to confirm that the gate is not stuck open, a stuck open wastegate can starve an engine of power or cause it to slowly build boost. During the examination, check the integrity of the line that connects to the turbo’s diaphragm, which senses boost, if that line is cracked or leaking, this will cause the engine to over boost.
If your turbo is a variable vane turbo look for carbon build up in the vanes which could lead to the vanes sticking and as a consequence solenoid overload and failure.
Check Oil Lines
If the turbocharger has had a bearing or seal fail, check the integrity of the oil feed, and drain holes to ensure they are not clogged up with sludge. Check the compressor inlet to see if impeller damage is evident. Also check for excessive oil film and smooth movement of the shaft. Keep in mind that if the turbo you are checking has a floating bearing there will be movement evident, however if the movement is sufficient the cause the fins to hit the housing the wear is excessive and the turbo needs repair work.