Turbine diagnostics and repair
- The largest choice of reasonable solutions: repair, new or remanufactured unit
- Repair a faulty unit with a working one in 30 minutes
- Own stock of turbines
Where to find us
What Turbines Can Be Repaired at STS
A turbocharger, or as it is usually called more simply, a turbine, is an important engine component responsible for increasing power and torque. Turbochargers are used in the vast majority of modern diesel vehicles and a significant portion of gasoline cars. Due to their design features, this component has to work in very difficult conditions, so periodic turbocharger restoration in Warsaw is sometimes simply necessary. How can you determine that the component has failed and where to perform turbine repairs in Warsaw?
Essentially, the company regenerates any types of turbochargers used in both cars and other equipment: on tractors, boats and motorboats, and even in tanks. The operating principle of turbines in most internal combustion engines is roughly similar: they usually consist of two impellers connected by a common shaft, each placed in its own round housing (often called a "scroll").
Into one "scroll" exhaust gases flow, which rotate the "hot" impeller, and into the other, "cold" one, the impeller is designed to draw in external air and supply it under pressure to the engine's intake manifold. Increasing oxygen supply also allows increasing fuel supply, and thus enhancing engine power and efficiency. Turbocharged engines, especially diesel, have the highest efficiency among all internal combustion engines. Therefore, turbocharger service in Warsaw is a very sought-after service.
Automotive turbines can be divided into two classes according to the geometric features of their internals:
- Conventional, with stationary impellers of unchanging shape;
- Turbines with variable geometry.
The second type is equipped with an additional ring with movable blades of a special aerodynamic shape, which increases boost efficiency and eliminates turbocharging drawbacks (so-called turbo lag).
Furthermore, there are several engine turbocharging configurations:
- Single turbocharging – the most common type.
- Biturbo – sequential installation of two compressors. In this type, one turbine can be main, and the other auxiliary.
- Twin turbo. Parallel placement of two identical units (for example, with a V-type layout).
- Quad turbo. A variant of the previous type for multi-cylinder engines of sports cars.
- Twin biturbo. Double biturbo. Like the previous type, it is encountered very rarely.
In general, turbocharger repair in Warsaw of any types and configurations does not have significant differences and can be qualitatively performed in a professional workshop equipped with specialized equipment.
Turbine Malfunctions That Can Be Repaired at STS
Most turbocharger failures have their root cause in the very complex conditions in which the component must work. The key is the temperature difference between the "hot" and "cold" scrolls. Into the first impeller, heated exhaust gases flow directly from the combustion chamber, into the second – atmospheric air, often additionally cooled in the intercooler to improve mixture combustion quality.
Main Signs of Turbocharger Failure:
- Power drop and deterioration of vehicle dynamics;
- Reduction of boost pressure level (if sensor and indicator are present);
- Increased motor oil consumption;
- Blue or black smoke from the exhaust pipe;
- Squealing in the turbine area.
Their cause can be a quite wide range of malfunctions that can be combined into several groups:
- Turbocharger housing damage – cracks, chips, scratches.
- Destruction of the turbine wheel and blades.
- Failure of turbine components: shaft bending or destruction, compressor wheel, nozzle apparatus blades, bearings.
- Bypass valve (Wastegate) malfunctions.
- Actuator and position sensor failures.
All these problems are caused by both overheating and the use of low-quality motor oil or its untimely replacement, foreign objects getting inside the turbine, as well as natural wear and aging of turbocharger components.
Turbocharger Replacement or Restoration in Warsaw – What to Choose
A turbine is not the cheapest car part, so when repairing, you need to consider the nature and complexity of the malfunction. Small breakdowns of auxiliary parts such as sensors, bearings, and similar ones are solved by disassembling the turbine and do not require its replacement. However, in case of serious housing damage or its critical wear, the turbocharger should preferably be replaced. But even then, you can find optimal problem-solving options – for example, replacing the faulty turbine with a quality-restored one from the STS exchange fund.
Turbocharger Restoration Process
Turbine repair in Warsaw at our workshop consists of the following stages:
- Node dismantling and transfer to the repair department.
- Housing cleaning.
- Defect analysis to determine the cause of the failure.
- Electronic component diagnostics.
- Replacement of damaged and worn parts.
- Balancing and adjustment of the unit on professional equipment.
After turbine restoration in Warsaw, they can be installed in a car using a new gasket set of our own production and assembly. As a result, the client receives a completely overhauled compressor, identical to a new one both in terms of performance and residual resource. STS provides a 6-month warranty for all its work and spare parts used.
Turbine regeneration prices in Warsaw depend on the complexity of work and vehicle modification. However, in general, it is much more advantageous and cheaper than buying and installing a new unit.
Problem: A well-known logistics service provider brought in three electric vans for repair after their high-voltage batteries failed. In one of them, the battery was dismantled.
Problem: The high-voltage battery is discharged and cannot be charged. The car does not accept a charge because the electronics do not recognize the connection of the charging gun.
Problem: A sharp drop in driving range and the vehicle switching to emergency mode with reduced power (“turtle mode”).
Problem: The problem with the car was the incompatibility of the Chinese GB/T standard charging system with European charging stations. This created difficulties for the owner of the Audi Q4 e-tron, since the car, produced for the Chinese market, could not charge at European stations with the required speed and reliability.
Problem: Failure of Toyota hybrid batteries is a common problem that our customers come to us with. The battery cells degrade, making it impossible for the car to operate normally.
Problem: We received an electric car with very discharged traction batteries. The problem is typical for the Fiat 500. During idle time, the batteries discharged below the permissible level, and the car's electric motor stopped starting.
Problem: The Hyundai Kona made a rather loud noise. The customer diagnosed the malfunction on his own - in his opinion, the gearbox was the cause of the extraneous sounds.
Problem: We received an electric motor manufactured by Continental, which was installed on an Opel vehicle for the Chinese market. The motor seized after the car was involved in an accident.
Problem: There was water and rust inside the rail, which damaged both the needle bearing in the cover and the torque sensor, i.e. both the mechanical and electrical parts
Problem: Two electric vehicles arrived at our workshop: a 2018 Kia e-Soul with noise in the motor area and a Mercedes-Benz EQC with an "insulation fault to ground" error. In both cases, the faults turned out to be quite typical and caused by design flaws in the vehicles.
Problem: We received a Hyundai Ioniq EV with complaints of whining noise during driving. An initial inspection revealed that the sounds are coming from the motor, on the side opposite to the gearbox.
Problem: In the case of a critical discharge of a low-voltage battery (12–48 V), the electronics prevent charging because it is dangerous with Li-Ion batteries. The manufacturer recommends discarding fully functional batteries and replacing them with new ones. This is expensive.
Problem: Failure of Toyota hybrid batteries is a common problem that our customers come to us with. The battery cells degrade, making it impossible for the car to operate normally.
Problem: Land Rover Range Rover Sport 3.0 SDV6 Hybrid AT AWD - the hybrid system did not work, the VBB was in emergency mode. The car was running only on diesel fuel, the low-voltage battery was not charging.
Problem: None of the car's systems were working at all, it wasn't even possible to raise it on a lift because the air suspension didn't activate either. I had to install the Porsche near the repair box on "goat" stands.
Problem: In Opel Astra H vehicles, the electric power steering pump often fails. The cause can be either corrosion or damage to the unit due to careless driving.
Problem: IThe specific placement of the steering rack in many Audi models allows moisture to penetrate the control unit of the electric power steering, causing corrosion of components and failure of the unit.
Problem: Steering rack leakage from under the tie rod dust cover
Problem: Steering rack leakage from under the tie rod dust cover
Problem: The owner of a Citroen C4 Picasso car came to us with a complaint about poor engine performance. The car literally could hardly drive: the engine would not rev above 2000 rpm and did not develop the necessary power. Fuel consumption increased significantly. The problem lies in the car's clogged particulate filter.
Problem: We were approached by the owner of a 2017 Citroen Berlingo with complaints of a knocking steering rack.
Problem: A Mercedes-Benz B250 electric vehicle, equipped with a Tesla motor, arrived at the service center with insulation fault errors and coolant ingress inside the electric motor.
