Remanufacturing Turbochargers

The Process

Owen Developments has staff and machinery dedicated to ensuring that the companies’ exacting standards of quality for remanufactured products are met consistently. This is a brief guide to the processes used when remanufacturing turbochargers at Owen Developments. If this is a service you require, contact Owen Developments by phone or email for advice before sending in your turbo with a filled-out Turbo Inspection Form and your contact details.

Arrival/Stripping

Once a turbo has arrived at Owen Developments the Turbo Inspection Form that came in with the turbo is consulted, this gives vital information on what to expect and look for as the unit is stripped as well as the details of the turbocharger’s owner. The turbo is then stripped to its component parts ready for cleaning and inspection. There are some components which are discarded and replaced regardless of their condition, such as ring seals, as they are the first to fatigue and wear.

Cleaning

The parts then go through a five-stage cleaning process.  This may seem like overkill, but in order to inspect a unit for faults properly it must be clean; any carbonised oil or fuel must be removed so that the technicians can see what they are doing and the VSR rigs aren’t contaminated later in the rebuild. Ferrous metals, especially if they’re cast, can rust very quickly once they’re cleaned this effectively so these parts are treated with a rust inhibitor to prevent corrosion. Some components are inspected as they are cleaned, such as bearing cartridges, as any debris present heavily indicates wear and damage.

Inspection

With the turbo apart and cleaned it can now be inspected in detail. Any parts which are outside manufacturer tolerance, contaminated or otherwise damaged will be replaced with new parts.

Assembly and Balancing

Once the go ahead had been given reassembling the turbo can begin. As the turbo has been used the turbine wheel and shaft will be rebalanced. Over time with wear some material will have been lost, so the shaft will usually be subtly out of balance.

With the shaft rebalanced the core can then be reassembled with new parts as needed and balanced on one of the VSR machines. At Owen Developments great pride is taken in having extremely tight balancing tolerances and this extends to remanufactured turbochargers too. All remanufactured turbos leave Owen Developments balanced to a better standard than the OEM specifies. For a more detailed explanation of core balancing, follow this link.

Now the core is assembled the compressor cover and turbine housing will be reattached to the core in the correct orientation. If the flange face on the turbine housing is distorted it will be skimmed so the gasket can seal the join effectively.

Setting the Actuator

The wastegate actuator assembly is then re-fitted (assuming the turbo in question has one) and calibrated. This is an important step in ensuring reliable use, preventing overboosting and other potential problems.

Finishing

The turbocharger is then subject to a final quality control inspection before it is signed off to leave Owen Developments. When these checks have been passed the turbo receives an Owen Developments tag and unique serial number signifying that it has passed quality control and is ready to be fitted on another vehicle.

Owen Developments

Owen Developments is one of Europe’s premier high performance forced induction specialist, with a proven track record of supplying turbochargers to a global customer base covering the motorsport, performance aftermarket and OEM sectors. Owen Developments is the sole turbo supplier to the British Touring Car Championship, the highly competitive one-make MINI Challenge and Indy Lights (Indycar’s feeder series).

 


 

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Owen Developments Ltd
28 Kingston Business Park
Kingston Bagpuize
Oxford
Oxfordshire
OX13 5AS

t: 01865 821062
w: www.owendevelopments.co.uk
e: enquiries@owendevelopments.co.uk
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