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Turbo overhaul for Porsche

Turbo overhaul for Porsche 930, 965 Turbo and 993, 996 TT.

We offer this service for the following models

  • Porsche 930 3.0 Turbo
  • Porsche 930 3.3 Turbo
  • Porsche 965 3.3 Turbo
  • Porsche 965 3.6 Turbo
  • Porsche 993 TT including Turbo S
  • Porsche 996 TT Including Turbo S
 
If you would like to K-Jetronic overhaulIf you would like to make a DME modification or combine it with a Mahle Motorsport upgrade kit, please contact us first.
Register your revision immediately

There are 3 options:

Option 1

STANDARD REVISION

Option 2

STANDARD REVISION WITH UPGRADE

Equipped with upgraded bearings, KKK motorsport seals and VSR high-speed bearings

Balanced according to race specifications. Ideal if you

plan to drive (in the future) with increased turbo pressure using a software upgrade.

Option 3

OPTION 2 + EXTRA POWER THROUGH HYBRID TURBO APPLICATION

Approximately 400 hp for the 3LDZ Turbo (P930 74-89) and K27 variants (P965 Turbo)

Approximately 650 hp for the K16 variants (P993TT & P96TT)

CAUTION:

Your own KKK turbo, which comes with the car, is always reconditioned. This is not a trade-in system! For all options, an undamaged turbo must be sent in first.

If your turbo is already damaged, additional costs will be charged. These costs cannot be estimated in advance.

Revision process

Step 1

START

After receiving the turbo, it is disassembled and analyzed. The components are then thoroughly cleaned. Finally, the components are sandblasted.

Step 2

Surface treatment

The cast iron parts are sandblasted with a coarse grit. A different blasting machine, using ceramic glass beads, is used for the aluminum parts.

After sandblasting, the bearing housings are washed with coarse blasting grit and also with ceramic glass beads.

The bearing housings are then ultrasonically cleaned to ensure no sand or dirt remains. Finally, all components are greased to prevent rust formation.

Step 3

Control

First, the turbine shaft is checked for straightness. This is done using a straightness meter with a dial gauge accurate to 1,0 micrometer.

The lower positions of the turbine shaft and the turbocharger bearing housing are checked with micrometers to ensure they are within the permitted tolerances. The compressor wheel is blasted with glass beads and inspected for hairline cracks using metal testing. If all components are technically sound, the balancing process can begin.

Step 4

To balance

Balancing is one of the most important steps in turbo reconditioning. The reason for this is simple: modern turbochargers reach speeds of over 220.000 rpm. Any imbalance at these speeds will eventually or immediately lead to serious damage to the turbocharger. Dynamic wheel balancing is essential for turbo balancing. This means balancing with two correcting surfaces.

Each component is balanced individually. After all components have been individually balanced, the rotor is installed. This rotor is also dynamically balanced. For this, we use a Schenck balancing machine. The components must then be assembled in such a way that the turbo forms a rotating assembly.

Since not all parts can be balanced individually, such as the thrust ring etc., the rotating part as a whole must be rebalanced using a VSR balancing machine.

For this, we again use a Schenck balancing machine, the Schenck 110MBRS VSR balancing machine, number 1, which is required and approved by all turbocharger manufacturers. This balancing step is performed at the speeds that the engine reaches. This is an ideal final test before the reconditioned turbocharger is installed on the engine. If a turbocharger passes the final inspection, it is in perfect working order. The extremely precise balancing processes, in particular, ensure that no detail is overlooked.

Step 5

Final adjustment

After balancing, the clearance in the internal bearings is checked and compared to the turbocharger manufacturer's specifications, after which the turbocharger is further adjusted. Finally, the actuator is set to the factory default value.

Click here to register your revision

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