Head OfficecarwOOd MOtOr Units LtdHerald Way, BinleyCoventry CV3 2RQUnited Kingdomtel +44 (0)2476 449533 fax +44 (0)2476 452074 email carwood@carwood.co.uk

TURBoCHaRgeR RemanUfaCTURing SpeCialiSTS

TURBOCHARGER

TURBoCHaRgeR RemanUfaCTURing SpeCialiSTS

ExpErts in turbochargErsthe carwood Ollerton facility is housed in a specially developed factory in newark UK. they remanufacture units for the most demanding applications such as defence vehicles, where total reliability is essential in conflict or battle theatre situations or for off road applications where vehicles operate the hardest duty cycles in the harshest environments. carwood Ollerton staff have over 30 years experience in producing a turbocharger of the highest quality that will meet or even exceed Oe specifications. investment in the latest technology, such as the advanced schenck 110Mrs computerised balancing system, keeps carwood at the leading edge of production techniques.

built-in QualityRigorous procedures enable quality control from small batch through to volume production, every unit is precision balanced as part of Carwood’s remanufacturing process. High levels of oe specification new parts are fitted in 100% of units.all operations are conducted on site by factory trained time served engineers. facilities include a machine shop, inspection area, paint and finishing shop, balancing room as well as conventional dismantling, cleaning and assembly lines and a unique final test machine. The entire operation conforms to iSo9001:2008 and iSo14001:2004.

carwood ollErton capabilitiEs includE: • Conventional Turbochargers • Variable Vane Turbochargers (VVT) • Passenger car, commercial vehicle, generator,

defence, plant and specialised applications

thE procEss in dEtailfull dismantling and multi-stage cleaningon receipt of core or customer’s units each one is carefully inspected for conformity to type, general condition and acceptability. Units with impact damage, stress fractures, cracks, high corrosion levels, evidence of chemical attack or other contamination are rejected immediately and not used in any way for the remanufacturing programme.

acceptable core is carefully dismantled using appropriate engineering techniques. each component is then further inspected, only suitable cast housings and non-wearing machined parts are passed on to the multi-stage cleaning process. items are hot washed, solvent washed, tumble shot cleaned or cabinet bead blasted as appropriate. Carwood uses biodegradable detergent and new generation safety solvent with patented chemical clarifiers – this extends solvent life and reduces environmental impact.

TURBOCHARGER

high Quality rEmanufacturing using thE vEry latEst tEchnology

inspEction, mEasurEmEnt and appraisal after cleaning components are properly inspected and measured for wear. if they conform to specification they are cleared for use in the remanufacturing processinspection techniques employed include: • full surface visual inspection • Crack detection • micrometer and digital instrument dimension measurement • Test gauge and control sample comparison • pressure or vacuum testing of actuators

Kitting with nEw parts each and every turbocharger is kitted with these new parts as a minimum standard:• Journal bearings• Thrust bearing• Turbine piston ring• Compressor piston ring• J bearing retaining rings• “o” rings for seal plate & cover• Shaft nutThis kit is combined with the compressor and turbine wheels, shaft and seal housings prior to assembly.

componEnt balancing The turbine and compressor wheels are dynamically balanced as components on a giesler high speed horizontal balancing machine The Compressor wheel is then assembled to the turbine shaft and wheel and balanced as a matching pair.

sub assEmblyonce the shaft and wheels have been balanced as an item they are sub assembled with the journal bearing housing to form the turbocharger core.

corE assEmbly balancingfor complex VVT units the facility to balance a sub assembly core on a Schenck 110 mBS balancing machine is available. This state of the art machine has automated and computerised operation that tests a core assembly at operational speed with the ability to run up to 250,000 rpm. it ensures high specification of balancing to give minimum vibration and long service life.

actuator tEsting and finishingThe pressure or vacuum operated actuator unit used on turbochargers is tested and operated to check for integrity and conformity to specification. electronic actuators are computer-tested on specialised automatic equipment.The units are sprayed to a high finish for cosmetic appeal and durability.

final assEmbly and inspEction once the core is balanced it is assembled with the actuator, turbine and compression housings with bolts tightened to the required torque settings. all cast housings are immersed in rust inhibitor prior to assembly. The unit is again checked visually for fit and finish and to ensure the housings are free from damage. all apertures are sealed and protective caps fitted where required.

full opErational tEstevery Carwood turbocharger undergoes full operational performance checks, producing a print out of results from its computerised control centre.

pacKagingafter final inspection all units are wrapped in polythene with anti-corrosive packets. final carton packaging is available in plain box or to customer requirements. military specification packaging can also be provided.

www.carwood.co.uk

Head OfficecarwOOd MOtOr Units LtdHerald Way, BinleyCoventry CV3 2RQUnited Kingdomtel +44 (0)2476 449533 fax +44 (0)2476 452074 email carwood@carwood.co.uk

TURBOCHARGER

carwOOd OLLertOnUnit 1 & 2 Whitewater placemaun Way, Boughton ind est Southollerton, nottinghamshire ng22 9ZDtel 01623 863 600 fax 01623 863 606email simonmitchell@carwood.co.uk

Carwood is a world class remanufacturer of vehicle diesel fuel injection, electrical and ancillary systems. We are also a major aftermarket supplier of specialised vehicle components.

TURBoCHaRgeR RemanUfaCTURing SpeCialiSTS

KEY PROCESSESFull dismantling and multi-stage cleaning • inspection, measurement and appraisal •Kitting with new parts •component balancing •sub assembly •core assembly balancing •Final assembly •inspection •computerised perFormance test •pacKaging

carwood rEmanufacturing We have over 40 years remanufacturing experience and expertise covering diesel, electrical and other types of special rotating machines. Applications range from large fighting vehicles and off road equipment to small passenger car or stationary engines.

driving principlEs Carwood are committed to maintaining the very highest standards in remanufacturing, for which we are widely known, and includes such key measures as:• OE materials, processes and quality controls • Partnerships with systems manufacturers for

technology, information and training • Investment in people skills and development• Investment in state of the art equipment for

remanufacture and testing• Partnership with customers to exceed expectations

consErvation through tEchnologyCarwood remanufactured products are found in the aftermarket parts programmes of leading manufacturers and are used by many major organisations. Carwood customers include Aston Martin, Bentley, Caterpillar, Dennis Eagle, Finnings, Jaguar Land Rover (JLR), Perkins and the UK MOD and Royal Navy. Remanufacturing is a growing form of recycling in the automotive industry. It enables the re-use of high cost, high energy elements of an assembly without compromising on the performance or future life expectancy of the unit. This clearly conserves the resources of the planet in terms of both the raw materials and energy used in production as well as reducing pollution by minimising the carbon footprint.

bringing oE Quality to thE aftErmarKEtCarwood excel in premium quality medium to high volume turbocharger remanufacture. The high level of new parts ingress and rigorous procedures combined with the state of the art inspection, testing and balancing techniques ensures consistent performance and reliability. We work with customers to meet or exceed OE specifications and match their needs with an environmentally responsible product programme.