Main turbocharger remanufacturing facility located in Northampton, UK.
This is where your old, failed and worn out turbochargers are sent for the start of a process, which will completely re-engineer every individual component part. Then on to turbo assembly, and the VSR test procedure, and finally packing and dispatch.
This remanufacturing facility was opened in 1981, and has undertaken several refurbishments and updates itself during this time, plus considerable investment in specialist machinery. In early 2011 the floorspace was doubled to accommodate the huge increase in turbo servicing. We believe this facility is probably the most adaptive passenger car and light commercial vehicle turbo remanufacturing facility in the world. We hope you enjoy your tour.
Turbochargers start the remanufacturing process by initial inspection and grading. Each turbo is carefully stripped into individual components ready for degreasing. Special equipment is required to disassemble a turbocharger without it sustaining component damage.
At this point all bearings, sealing rings, studs, bolts and hoses are discarded, as they will never be reused in a quality Turbo Technics remanufactured turbo.
Individual components are moved in large batches for either a further cleaning process or to Turbo Technics’ engineering works for reclamation. Extensive use is made of in-house machining facilities in the refurbishment of components, and in some cases the manufacture of new component parts.
Turbo Technics’ machinery workshops are operated by a very experienced workforce. A high degree of accuracy is required on many turbo components, and with fully computerised milling and turning operations, these high standards are maintained over thousands of machined components.
All turbocharger components are minutely inspected, and wearing parts are replaced as a matter of course. Components not meeting the required standards set by Turbo Technics are replaced with brand new items. To achieve the high standard set by ourselves, only brand new bearing and seals are used throughout. Housings are machined, actuators tested, wastegates overhauled, bearing housings inspected and turbine wheels examined.
Many items will not pass the close scrutiny of the tests and measurements conducted at this stage, and will subsequently be rejected. Approximately 60% of components will be reclaimed and will proceed to a final cleaning process, followed by quality control, and finally, ending in a Turbo Technics service-exchange turbocharger.
The assembly of each turbo is only carried out by hand using very experienced staff whose knowledge in this field is unprecedented. Turbochargers are assembled in clean areas equipped with the many specialised service tools and measuring equipment necessary.
Once the rotating components are assembled into the bearing housing, this complete assembly then undergoes a very rigorous test. It is placed into the Turbo Technics VSR balancing machine, which automatically drives the turbine wheel, using compressed air, up to speeds reaching 250,000 RPM (depending on the turbo’s size). While spinning, the machine measures the tiny amount of imbalance created by the rotating mass and calculates the procedure for correcting this imbalance.
The skilled machine operator will then make adjustments to the rotating assembly until the vibration results are below the prescribed limits. A certificate records the vibration limits of every turbocharger. This information is included with every Turbo Technics exchange turbo.
If this balancing process is not carried out using a Turbo Technics VSR machine, the result can be a turbo which will be noisy in operation and is very likely to suffer failure prematurely. Only the Turbo Technics VSR machine measures imbalance to the speeds necessary to be an effective test.
Once the turbocharger rotating assembly has passed this stage, it goes on to be fully assembled into its compressor and turbine housings. The alignment of each housing is critical as any inaccuracy will prevent or delay the turbo being fitted onto the engine. We use an orientation rig, also designed and manufactured by TT, to ensure accurate alignment is maintained time after time. The orientation rig is accurate to within a half a degree and is compatible with nearly all turbocharger models.
The next operation involves fitting the wastegate and actuator assembly. These two components control the boost pressure the turbo will produce. All Turbo Technics exchange turbochargers originally manufactured with an actuator, are supplied with an actuator. These are calibrated to the settings specified by the original manufacturer, using the orientation rig. This ensures that in most cases, no further boost pressure adjustments are necessary, after the turbo is fitted onto the vehicle. This saves time and adds reliability.
Final inspection is carried out, and a unique Turbo Technics identity plate attached to the turbo. This records all relevant information for future reference.
This completes the manufacturing process. The finished turbo is ready to fit to a vehicle.