Real-time Supercharger Teardown

[fitzydude]

I picked up a damaged supercharger on Craigslist from a 2015 A7 with 10k miles on it. I was planning on using it on my car, but it's a little too damaged for me to use the whole thing. Now I'm going to gut it and send out a few parts to some members on here and maybe swap the internals for mine with 111k.

I figured I'd post some pics on here and get some help along the way.

http://i274.photobucket.com/albums/jj249/fitzydude/Mobile%20Uploads/IMG_20160417_113038.jpg

Here's a pic of the damage. The car was in a wreck and it looks like it bent the water inlet flange and took a chunk out of the bracket that holds the front belt cover on
http://i274.photobucket.com/albums/jj249/fitzydude/Mobile%20Uploads/IMG_20160416_174114440_HDR.jpg

[fitzydude]

Throttle body and map sensor were easy enough! Any takers??http://i274.photobucket.com/albums/jj249/fitzydude/Mobile%20Uploads/IMG_20160417_114626.jpg

[fitzydude]

7 bolts held in the bypass valve. Why can't I just weld this thing shut?!?

http://i274.photobucket.com/albums/jj249/fitzydude/Mobile%20Uploads/IMG_20160417_115503.jpg

[fitzydude]

Here is a comparison of supercharger oil

Here is new supercharger oil
http://i274.photobucket.com/albums/jj249/fitzydude/Mobile%20Uploads/IMG_20160213_095000683.jpg

This is your supercharger oil at 10k
http://i274.photobucket.com/albums/jj249/fitzydude/Mobile%20Uploads/IMG_20160417_122838.jpg

Here is your supercharger oil at 110k
http://i274.photobucket.com/albums/jj249/fitzydude/Mobile%20Uploads/IMG_20160213_0949184612.jpg

I suggest changing somewhere between 10k and 110k ;)

[fitzydude]

Surprised by how much additional oil came out when I pulled the front off.
http://i274.photobucket.com/albums/jj249/fitzydude/Mobile%20Uploads/IMG_20160417_125238.jpg

[RedS-line]

SCARY, how did your supercharger die, it died at 110k miles?

[fitzydude]

SCARY, how did your supercharger die, it died at 110k miles?

Actually my supercharger is on the car and still rocking. This super charger with 10k from an A7 has some damage on the housing or plenum. So I'm tearing it down and selling/reusing what parts I can. Plus it's practice if I decided to work on my supercharger later.

[fitzydude]

Here are the scrolls coming out, I was worried I'd have to pull the gears on the front, but the whole thing just slides right out when you break the seal
http://i274.photobucket.com/albums/jj249/fitzydude/Mobile%20Uploads/IMG_20160417_131104.jpg

Just begging me to take the dremel to it!!
http://i274.photobucket.com/albums/jj249/fitzydude/Mobile%20Uploads/IMG_20160417_133352.jpg

[fitzydude]

Does anyone have some pro-tips for removing the intercoolers without breaking them?

[DGVR6]

Do us all a favor.. Send the oil from the 100k+ charger and send it for analysis.
Would be nice to know what's going on with that

Nice pics btw thanks for taking the time to do this

[fitzydude]

Got the intercoolers removed... Do not try to pull or pry on these things to get them out. I started with the bent one first and tried pulling on the back gently. It came out but I ended up bending some fins and bending the flange on the back... On the good one I just beat the front with a rubber mallet and it just popped right out with no damage

http://i274.photobucket.com/albums/jj249/fitzydude/Mobile%20Uploads/IMG_20160417_151831.jpg

http://i274.photobucket.com/albums/jj249/fitzydude/Mobile%20Uploads/IMG_20160417_155102.jpg

[Dudemans4]

Does anyone have some pro-tips for removing the intercoolers without breaking them?

Rubber mallet got mine out

[jmaddr]

Love this thread. Thanks for doing this.


Sent from my iPhone using Tapatalk

[bhvrdr]

Love this thread. Thanks for doing this.


Sent from my iPhone using Tapatalk

I agree. Thanks so much.

mike

[fitzydude]

If anyone needs any parts from this I'll post them for sale on the classifieds. Thanks!

http://i274.photobucket.com/albums/jj249/fitzydude/Mobile%20Uploads/IMG_20160417_165434.jpg

[RWD2quattro]

I wish someone would develop a higher flowing IC coolers with less pressure drop by decreasing tube/fin count (larger). Stock IC fins/tubes look small, maybe we may see some gains there with an AMS or APR external cooler and secondary coolant pump? Any thoughts?
Thanks for taking the time to tear apart SC, I'm in for oil results.

[cchoi83]

Do us all a favor.. Send the oil from the 100k+ charger and send it for analysis.
Would be nice to know what's going on with that

Nice pics btw thanks for taking the time to do this

This.

[jrivera]

Good job!

[A.Bruno6]

This thread is great! Thanks for taking the time to do this!


Sent from my iPhone using Audizine mobile app

[xcnovanrunner]

Do us all a favor.. Send the oil from the 100k+ charger and send it for analysis.

Would be nice to know what's going on with that



Nice pics btw thanks for taking the time to do this


+1

[Pyromatic177]

Very interesting to see what makes our cars so fun taken apart! Lol. Nice thread.

[chaos2984]

where do you get the S/C oil from? Might have to change like every 30k or something.

[AudBoost]

where do you get the S/C oil from? Might have to change like every 30k or something.

ECS sells it: https://www.ecstuning.com/Search/SiteSearch/Supercharger_Oil/ES2099956/

[s4matty]

You can also buy the oil from Chevrolet..Cts v and vette use the same oil..It's only $6 a bottle,you need 2 bottles though.

Sent from my SM-G900W8 using Tapatalk

[Loe]

You can also buy the oil from Chevrolet..Cts v and vette use the same oil..It's only $6 a bottle,you need 2 bottles though.

Sent from my SM-G900W8 using Tapatalk

WOW @ the Audi tax on this fluid!

[amz]

I kinda wish teardowns like this were done with a gopro attached to their head. That way, not only do we get pics, but an informational video.

Thanks for the photo's though, this is great info!

[fitzydude]

I kinda wish teardowns like this were done with a gopro attached to their head. That way, not only do we get pics, but an informational video.

Thanks for the photo's though, this is great info!

Haha well that would just be me half drunk and cursing for 4 hours. I'll keep it in mind when I do something like this again.

[jimrobbington]

Haha well that would just be me half drunk and cursing for 4 hours. I'll keep it in mind when I do something like this again.
Hahaha

[jsh139]

And this, ladies & gentlemen, is where that sweet whine comes from :D


http://i.imgur.com/zHeKAXul.png

[amz]

And this, ladies & gentlemen, is where that sweet whine comes from :D


http://i.imgur.com/zHeKAXul.png

Really? Does the sound get transmitted through the lobes and then back into the intake? I'm curious why going from stock to, for ex, Roc Euro, produces such a dramatic change in SC whine if it's originating from those gears and not something in the compressor chamber.

[jrivera]

Straight tooth makes more noise than helical.

[OnEaNgRyBuNnY]

Really? Does the sound get transmitted through the lobes and then back into the intake? I'm curious why going from stock to, for ex, Roc Euro, produces such a dramatic change in SC whine if it's originating from those gears and not something in the compressor chamber.

That's what I would assume and the whine does sound like that of straight cut gears.

[jimrobbington]

Really? Does the sound get transmitted through the lobes and then back into the intake? I'm curious why going from stock to, for ex, Roc Euro, produces such a dramatic change in SC whine if it's originating from those gears and not something in the compressor chamber.
The stock intake is designed to muffle as much sound as possible

[jsh139]

That's what I would assume and the whine does sound like that of straight cut gears.

Aw, snap! Someone said the magic words! [:D]


http://youtu.be/dmJH84FnQa8

[amz]

That's what I would assume and the whine does sound like that of straight cut gears.


The stock intake is designed to muffle as much sound as possible

Huh, cool I guess. RocEuro is a great investment for letting the sound out :D

[jimrobbington]

Huh, cool I guess. RocEuro is a great investment for letting the sound out :D
Yeah, it's not that an intake causes more noise, you are just removing all the stuff that helps cancel the sound that's already there

[B8_Jim]

And this, ladies & gentlemen, is where that sweet whine comes from :D



It isn't.

[cspcrx]

Aw, snap! Someone said the magic words! [:D]


http://youtu.be/dmJH84FnQa8

that hurt to listen to!

[SquiddyB6S4]

Straight tooth makes more noise than helical.

That's why us B6/7 S/RS4 guys have supercharger whine . . . those wonderful straight cut gear driven accessories that make so much dang sense [:)] "But, your honor, they pack so much power transmission ability into a small and lightweight space!"

Fitzydood - Greay work. Also, you are funny when you write the same as when you speak.

[OnEaNgRyBuNnY]

It isn't.

Then where???

[B8_Jim]

Then where???

I probably won't explain this very well, but I'll give it a shot.

Roots type blowers in effect take a slug of air from the intake side and "pump" it to the manifold side. As the lobes rotate, they seal off from the intake port and after more rotation the outlet port opens up. After more rotation, all the air is forced to move to the manifold side.

If the intake manifold is above ambient pressure - when the rotation gets to the point where the outlet port first opens up, a pressure wave is formed as the higher manifold pressure is opened to this lower pressure area. As the lobe rotates around the new volume is reduced to zero size thus moving all the air to the manifold side.

The sound you hear are these pressure waves rushing back and forth as the outlet ports open up and then the air is moved completely to the manifold side, and the next lobe opening, etc... To make a lot of sound the manifold has to be sufficiently above ambient - thus the chargers are loudest when you are WOT and they bypass valve is completely closed and is building max boost.

Since the sound is from air pressure waves within the charger and intake air flow path - changing the factory intake (box) and intake tube (damper) to an open air filter really let the sound out. If the major source of sound was the drive gears, changing the intake would have very little effect on the sound - they are not within the intake air flow path.

[amz]

I probably won't explain this very well, but I'll give it a shot.

Roots type blowers in effect take a slug of air from the intake side and "pump" it to the manifold side. As the lobes rotate, they seal off from the intake port and after more rotation the outlet port opens up. After more rotation, all the air is forced to move to the manifold side.

If the intake manifold is above ambient pressure - when the rotation gets to the point where the outlet port first opens up, a pressure wave is formed as the higher manifold pressure is opened to this lower pressure area. As the lobe rotates around the new volume is reduced to zero size thus moving all the air to the manifold side.

The sound you hear are these pressure waves rushing back and forth as the outlet ports open up and then the air is moved completely to the manifold side, and the next lobe opening, etc... To make a lot of sound the manifold has to be sufficiently above ambient - thus the chargers are loudest when you are WOT and they bypass valve is completely closed and is building max boost.

Since the sound is from air pressure waves within the charger and intake air flow path - changing the factory intake (box) and intake tube (damper) to an open air filter really let the sound out. If the major source of sound was the drive gears, changing the intake would have very little effect on the sound - they are not within the intake air flow path.

This makes more sense, and helps answer my question .

[TorsenForcin]

The sound you hear are these pressure waves rushing back and forth as the outlet ports open up and then the air is moved completely to the manifold side, and the next lobe opening, etc... To make a lot of sound the manifold has to be sufficiently above ambient - thus the chargers are loudest when you are WOT and they bypass valve is completely closed and is building max boost.


^ agree. An example that bears this out in my mind is the several motorcycles with gear driven cams that I've owned. Even at idle, the gears could be distinctly heard whirring/whining away. Despite the Roc-Euro, I cannot hear any SC whine at idle. If it was gear on the SC making the noise, I'd expect to hear the whine regardless of rpm.

Thx to the OP for these pics!

[MattACK]

Here are the scrolls coming out, I was worried I'd have to pull the gears on the front, but the whole thing just slides right out when you break the seal
http://i274.photobucket.com/albums/jj249/fitzydude/Mobile%20Uploads/IMG_20160417_131104.jpg

Just begging me to take the dremel to it!!
http://i274.photobucket.com/albums/jj249/fitzydude/Mobile%20Uploads/IMG_20160417_133352.jpg

I wouldn't touch any of that with a dremel... The inlet and outlet is opened up as much as it can be and opening up the outlet anymore will hurt power.

[fitzydude]

I wouldn't touch any of that with a dremel... The inlet and outlet is opened up as much as it can be and opening up the outlet anymore will hurt power.

The Inlet just got 10 times larger.

http://i274.photobucket.com/albums/jj249/fitzydude/Mobile%20Uploads/10-donald-trump-debate.w750.h560.2x.jpg

[B8 S4]

The Inlet just got 10 times larger.

http://i274.photobucket.com/albums/jj249/fitzydude/Mobile%20Uploads/10-donald-trump-debate.w750.h560.2x.jpg

Haha yesss, did you port it? If so please do a dyno before and after to prove if it is a worth while mod.

[stereojorge]

7 bolts held in the bypass valve. Why can't I just weld this thing shut?!?

http://i274.photobucket.com/albums/jj249/fitzydude/Mobile%20Uploads/IMG_20160417_115503.jpg

You could, but then how would you in the future be able to install an Analog Boost Tap for a P3? [emoji48][emoji48]

[danmm7]

Maybe i missed it, but was there a specific oil drain plug and filler for the SC?

I am very interested and drain/refill of my SC oil, but how do i get the fluid in/out?

Thank you!

[fitzydude]

Maybe i missed it, but was there a specific oil drain plug and filler for the SC?

I am very interested and drain/refill of my SC oil, but how do i get the fluid in/out?

Thank you!

Check out my other thread

http://www.audizine.com/forum/showthread.php/695076-Changed-my-supercharger-oil?highlight=supercharger+oil

[jstarr427]

Sweet! cool to see the insides of that thing! what supports the rear of the scrolls? looks like needle bearings in the rear of the housing? how are those lubed?

Also, would it make sense to pop that front cover off to ger the rest of the oil out when changing it? Mine is at 75k, and I'm thinking about doing it soon...

[Big_Daddy]

The whine is produced as a result of the pressure differential at the point of the air intake into the scrolls.
That's why the intake makes such a noticeable affect on the sound emanating from what is essentially an air grinder.

[fitzydude]

Sweet! cool to see the insides of that thing! what supports the rear of the scrolls? looks like needle bearings in the rear of the housing? how are those lubed?

Also, would it make sense to pop that front cover off to ger the rest of the oil out when changing it? Mine is at 75k, and I'm thinking about doing it soon...

The rear of the scrolls are set in needle bearings, I think I remember them being coated in blue greese, but I was drinking at the time..

And you could definitely remove the front cover to get more fluid out. It took quite a bit of acrobatics to get the amount of fluid I got out.

[BlownOne]

Sweet! cool to see the insides of that thing! what supports the rear of the scrolls? looks like needle bearings in the rear of the housing? how are those lubed?

Also, would it make sense to pop that front cover off to ger the rest of the oil out when changing it? Mine is at 75k, and I'm thinking about doing it soon...
The snout and gear housing comes off, but you need to check the torque spec before removing your bolts and you need some gasket maker to seal it back up. Removing it is the best way to completely clean inside (little metal shavings) and completely change the fluid. Fill until it is about even with the fill/drain hole.


The rear of the scrolls are set in needle bearings, I think I remember them being coated in blue greese, but I was drinking at the time..

And you could definitely remove the front cover to get more fluid out. It took quite a bit of acrobatics to get the amount of fluid I got out.
Yes the shafts of the rotors sit in needle bearing in the rear of the case, coated in blue high temp grease. I could imagine it would be a pita to try and get all the fluid out of that little hole lol

[bayonet14]

Thanks for the pics and write up!

[evanb]

Aw, snap! Someone said the magic words! [:D]


http://youtu.be/dmJH84FnQa8

Well that woke up every dog in the neighborhood.