In the spotlight
Want to stay informed of all the news about turbos? Read it below. From new techniques, turbo problems to solutions: we like to share it.
How does a turbo work?
A turbocharger, also known as a turbocharger, is a device that improves the performance of an internal combustion engine by supplying pressurized intake air. It works on the principle of a gas-dynamic compressor. You can read below what this is exactly.
The basic principle of a turbo is as follows:
- Exhaust gases : The turbo uses the energy of the exhaust gases released during combustion in the engine. These hot, exhaust gases are led through the exhaust port to the turbine of the turbo.
- Turbine : The turbine consists of a turbine wheel and a casing. When the hot exhaust gases flow over the turbine wheel, they cause a high velocity of the gas and set the turbine wheel in motion. The turbine wheel is connected to a shaft attached to the other side of the turbo.
- Compressor : On the other side of the turbo is the compressor, which consists of a compressor wheel and housing. When the turbine wheel rotates, it drives the compressor through the shaft. The compressor draws in air through an air filter and compresses it, increasing air pressure and density.
- Intake Air : The compressed air is then fed to the engine's intake manifold through an intercooler. Because the air is under pressure, more air can be pressed into the cylinders than with a naturally aspirated engine. This results in a greater amount of fuel that can be burned leading to increased power output from the engine.
- Lubricant and Cooling System : A turbo also has a lubricant and cooling system. The lubricant lubricates the rotating parts and helps to regulate the temperature. Cooling is essential to prevent overheating of the turbo and ensure its durability.
- The turbine wheel
- The turbine house
- Exhaust gas in
- Exhaust gas out
- The compressor wheel
- The compressor house
- Steel shaft
- Compressed air
By supplying the intake air under pressure, a turbocharger makes it possible to obtain a higher power output from an internal combustion engine without increasing the displacement. This allows cars to accelerate faster, make more power and have better performance, especially at higher speeds.
Learn more in this video from Cummins:
A turbo wears out and has specific maintenance requirements. Proper use is also essential to ensure the life and reliability of the turbo.Get in touchwith Turbo Service Belgium for all your questions.
Overhauling a turbo in 7 steps
Overhauling a turbo is a complex process that requires specific knowledge and experience. Turbos are sensitive components and incorrect overhaul can lead to further damage or reduced performance. With our innovative machinery, our turbo specialists ensure the best result. You can read the process of overhauling a turbo here.
Overhauling a turbo always starts with disassembly and analysis. We then thoroughly clean all parts and check them for any defects. After we test each component separately, we balance the entire turbo perfectly with our VSR machine. Then we adjust the actuator according to the factory values. Finally, we fine-tune a variable VNT turbo on our VTR flow bank so that they achieve optimum efficiency.
- Disassembly: First, the turbo is removed from the vehicle or machine. Then we take off the turbo housing and disassemble the compressor and turbine parts.
- Cleaning: Thorough cleaning of all parts is essential. Oil, carbon deposits and other contaminants from the housing, compressor wheel, turbine shaft, bearings and other components are cleaned. We prefer to clean some parts twice with our blasting machines. This is also followed by a treatment against rust formation.
- Inspection: All parts are examined for signs of wear, damage or other abnormalities. The compressor and turbine blades, the bearings, seals and other crucial components: everything is checked. We repair damaged or worn parts.
- Balancing: Balancing the turbo is a critical step to ensure smooth operation and durability. We balance the compressor and turbine parts using special equipment to prevent unwanted vibrations and damage.
- Seal and bearing replacement: We replace all seals, gaskets and bearings to ensure optimum performance and reliability. We only use original or high-quality parts.
- Assembly: we reassemble all cleaned and checked components. We strictly follow factory specifications and recommendations for bolt tightening and lubricant use.
- Testing: After the overhaul, the turbo must be thoroughly tested to ensure that it functions correctly. We do this with a turbo bank or by installing the turbo in the vehicle and checking it for performance, pressure levels and any leaks. Finally, we fine-tune a variable VNT turbo on our VTR flow bank so that they achieve optimum efficiency.
Overhauling a turbo is no easy task and requires expertise and precision. Don't you own this house? Then be sure to come by. Contact us for an appointment.
Discover our approach in this video:
From car to ship: turbos are everywhere
The history of the turbo begins in the early 20th century. You will not only find them in the car, but in many applications and sectors. Turbo Service Belgium has been specializing in turbos for more than 30 years. With a large stock and innovative machinery, we offer solutions in all brands for passenger cars, vans, 4x4s, trucks, agriculture, industry and shipping.
The turbo has a long history of evolution and today has become an important part of most internal combustion engines, both in the automotive industry and in other applications, playing a vital role in increasing power output and improving fuel efficiency .
The history of the turbo
Dr. Alfred Büchi, a Swiss engineer, designs the first turbocharger in 1905. He patents the concept of a turbocharger for use in internal combustion engines. A few years later, a German company develops the first jet engine powered by a turbocharger. This turboprop engine, known as the Jumo 004, was used in aircraft during World War II. After the war, General Motors (GM) introduced the first passenger car with a turbocharged internal combustion engine, the Oldsmobile Rocket V8. The turbocharger improves the power output of the engine. Rolls-Royce and Porsche are also jumping on the turbo bandwagon. In the 1980s and 1990s, the turbo broke through completely. Iconic turbocharged cars from this era include the Porsche 911 Turbo, the Mitsubishi Lancer Evolution and the Saab 900 Turbo.
A turbocharger is used in various vehicles, machines and industries. Here are some examples:
- Passenger cars : Turbochargers are of course widely used in passenger cars, both in petrol and diesel engines. They are used to increase power output, improve fuel efficiency and increase engine response. Turbocharged engines can be found in a wide variety of cars, from compact city cars to high-performance sports cars.
- Trucks and commercial vehicles : you will also always find a turbo in trucks, buses and other commercial vehicles. They increase the power and torque of the engine, providing benefits when pulling heavy loads and improving fuel efficiency in these applications.
- Ships : Turbochargers are used in marine engines, both in the marine and marine industries. They help to increase engine performance and optimize fuel consumption, which is especially important in long-distance cruising and the transport of large cargoes by sea.
- Aircraft : Turbos are indispensable in the aviation industry. They are used in aircraft engines, both commercial passenger aircraft and military aircraft. Turbos increase engine performance at high altitude and provide more efficient combustion in the engines, resulting in better fuel efficiency and higher speeds.
- Industrial machines : Finally, there are various industrial applications, such as power plants, oil refineries, chemical plants and other production facilities, where turbos cannot be missed. They are used to produce compressed air for industrial processes such as pneumatic tools, pneumatic conveying systems and other applications where compressed air is required.
Turbocharger technology continues to evolve and is used in various applications such as passenger cars, trucks, marine engines and industrial machinery. Modern turbo systems use advanced technologies, such as variable geometry turbos (VGT) and electric turbochargers, to further improve performance and efficiency.
Turbo Service Belgium offers solutions in all brands for passenger cars, vans, heavy duty, 4x4s, trucks, agriculture, industry and much more.Contact us.
The most frequently asked questions about a broken turbo
A turbo may look like a simple device, but it works quite complex. Do you have a turbo problem? Then it often requires the necessary expertise to identify exactly what the defect is. Below we list some questions that we often receive at Turbo Service Belgium.
- Hoe weet ik of mijn turbo kapot is?
Mensenwillen vaak weten hoe ze de symptomen van een kapotte turbo kunnen herkennen.De meestvoorkomende manieren om dit te herkennen zijn vermogensverlies, blauwe rook uit de uitlaat, abnormale geluiden (fluiten, sissen, malen) of olielekkage.
- What are the causes of a broken turbo?
High quality turbos generally do not fail on their own. It is always a consequence of another problem and therefore not a cause. Common reasons for turbo failure are blockages, contamination, too much or too little pressure or a foreign object. You can read all about it here.
- Can a broken turbo be repaired or should it be replaced?
The answer may vary depending on the nature and extent of the problem. That is why we at Turbo Service Belgium first carry out a professional and accurate diagnosis. You can then choose from recovery, a new turbo or exchange turbo.
- What are the costs of replacing or repairing a broken turbo?
This may vary depending on the vehicle, specific turbo model and complexity of the repair. After the diagnosis, we are happy to provide you with a transparent price proposal.
- How can I prevent future turbo problems?
This starts with following the correct maintenance schedule, using quality lubricating oil, avoiding excessive stress on the engine and watching for signs of potential problems.
Would you like advice on the best repair or replacement options? With more than 35 years of expertise, our door is always open.Contact us.
Where can you find the turbo number?
Would you like to know the price or stock for a certain type of turbo? Then it is very useful if you provide us with the correct turbo number. This way we prevent you from getting the wrong advice and we can deal with your question more quickly.
You will usually find the turbo number on an aluminum plate affixed to the compressor housing of the turbo. Not only are there an enormous number of types of turbos and applications, there is also a great deal of variation possible with the type plate. That is why looking up the article number can sometimes be a bit difficult. Can't find the turbo number on the compressor housing? Then look at the back of the inlet, the so-called back plate. Or at the lower house.
There are always several numbers on the rating plate. In addition to the article number, the manufacturer of the turbo often also states the OE number and a production code. It is not always clear which number is the item number. Sometimes it is at the top, sometimes at the bottom. So send us all the numbers: we know what to do with it.
Is the turbo number no longer readable?
It sometimes happens that the plate is missing or that it is no longer legible due to wear or oxidation. In that case, you can request an OE number from the manufacturer of the vehicle or machine.
If that also fails, we try to identify the turbo using photos of the turbo and with our 35 years of experience.Contact us here.
What is an electric turbo?
Thefirst turbo was produced in 1925launched. Meanwhile, innovation followed innovation. Today there is even talk of electric turbos. Why is this good news? The electric turbo is the solution for a well-known turbo problem: the so-called turbo lag. We explain how such an electric turbo works.
A turbo lag is an area in the rev range of the car in which the turbo does not have enough pressure. The car then does not deliver optimal performance. Over the years, several attempts have been made to tackle the turbo lag. Among other things with the variable turbo, dumpvales and double turbo systems. Without success, however.
The electric turbo differs from a conventional turbo by the drive, namely with an electric motor. In a traditional turbo, its operation is driven by the engine's exhaust gases. However, it can take some time for a turbocharger to fully ramp up, resulting in a delay in delivering additional power (also known as "turbo lag"). Those are times when the engine is not performing optimally.
The operation of an electric turbo
The electric turbo has been developed to prevent these problems. This is mounted in the intake pipe of the engine. The electric turbo is able to deliver the desired pressure within 250 ms. After the electric turbo has done its job, the conventional turbo takes over.
An electric turbocharger adds an electrically driven compressor to the turbo system. This electric compressor can quickly and instantly push additional air into the intake system without having to wait for the exhaust gases to build up pressure.
The electric turbocharger is powered by an electrical system, such as a battery or a 48V on-board system, and can be integrated with other technologies, such as regenerative braking or energy storage systems. The purpose of an electric turbocharger is to improve engine responsiveness and extend the power range, especially at lower RPMs.
Wat doet de EGR-klep met een turbo
We explain how a turbo works in this blog. Below we would like to tell you more about the EGR valve. What is it, how does it work and what is the influence on the turbo. So read on quickly.
What is the EGR valve?
The EGR (Exhaust Gas Recirculation) valve is part of the exhaust system in petrol and diesel engines. The main purpose of an EGR valve is to reduce nitrogen oxides (NOx) emissions by returning some of the exhaust gases to the engine's intake air. As a result, exhaust gas is less harmful to the environment.
The operation of the EGR valve
In a turbocharged engine, the air entering the engine is compressed by the turbocharger, increasing power output. However, this also creates higher temperatures and pressures in the combustion chamber, which can lead to the formation of nitrogen oxides, a potentially harmful exhaust gas component.
The EGR valve is used to return some of the exhaust gases to the intake side of the engine, mainly to the combustion chamber. By increasing the amount of exhaust gases in the combustion air, the combustion temperature drops, reducing the formation of nitrogen oxides.
EGR valve and engine management
This is beneficial from an emissions control point of view as it helps to meet regulatory standards for emissions. However, it can also affect the efficiency and performance of the engine, as the presence of exhaust gases can slightly affect combustion. Therefore, the EGR valve is usually controlled by the vehicle's engine management system, depending on operating conditions, to achieve an optimal balance between emissions and performance.
EGR valve and the turbo
The EGR valve indirectly affects the operation of the turbo. More specifically if the EGR valve does not close properly due to pollution. An EGR valve that is not closing properly causes air currents that in turn create boost pressure problems. It happens that an EGR valve breaks off and gets into the turbo.
Do you experience turbo problems? From analysis, overhaul to exchange turbo: at Turbo Service Belgium you can go for all turbo brands and all applications. Take todayContact.
Innovative machines for perfectly balanced turbos
We have been specializing in turbos for more than 30 years. Disassembling, analyzing and determining the problem of a broken or malfunctioning turbo is therefore a daily activity. After a thorough cleaning in one of our blasting machines and a treatment to prevent rust formation, we start overhauling or repairing.
From the turbine shaft, bearing housing to compressor wheel, we carefully check whether all parts are technically in order. We test each component separately and then fine-tune the turbo as a whole with our VSR balancing machine. Then we adjust the actuator according to the factory values. Finally, we fine-tune variable VNT turbos on our VTR flow bank so that they achieve optimum efficiency.
This testing and balancing is one of the most important process steps when overhauling or repairing a turbo. The speeds of modern turbos are so high that any imbalance leads to major damage. With our innovative machinery we can work quickly and accurately.
Common reasons for turbo failures
High quality turbos generally do not fail on their own. It is always a consequence of another problem and therefore not a cause. Read here common reasons for turbo failures and how to detect them yourself.
- A dirty particulate filter
- A clogged EGR system
- Too low oil pressure
- Excessive crankcase pressure or clogged crankcase ventilation system
- The suction of dirt, stones, debris or other objects
- Gebrekkige smering
- Fijn vuil of scherpe deeltjes in de motorolie
Are you experiencing a turbo failure? Then you can already check a few things yourself
- Does your vehicle or machine have too little power?
- Check that the filter, hoses and lines are clean and in good condition
- Check that the fuel injection system is in good condition and properly adjusted
- Check that the exhaust system, including the catalytic converter and DPF, is not clogged or damaged
- Make your vehicle or machine too noisy
- Check that the piping and support brackets are not loose or damaged and that the connections are in good condition
- Check for leaks or cracks in the intercooler
- Is there smoke nuisance or oil leaks?
- Check that the air filters are not clogged or blocked
- Check that the engine oil specifications are in strict accordance with the car manufacturer's recommendations
- Check that the oil drain line is clean and not clogged
- Check for excessive pressure in the engine crankcase and proper operation of the engine's breather system
- Check that hoses and connections are in good condition
- Check for engine block lubrication problems if oil or carbon deposits are found on exhaust manifolds or in the turbine
Wist je dat je via de kleur van de rook zelfs kan zien wat het turboprobleem is? In onderstaande video ontdek je er meer over:
Any questions? With more than 35 years of experience, we are happy to disassemble and analyze your turbo. So take quickContact.