Hybrid turbocharger: all for and againsts

Hybrid turbochargers are gaining popularity as a cost-effective and efficient way to increase engine power. But should you rely on this method instead of installing a new original part? Or perhaps professional remanufacturing of the old turbo might be a more reliable solution? What drives motorists to choose unconventional approaches to improving turbocharging, and how does it work? In this blog, we will explore all the nuances and help you understand whether upgraded turbochargers have a place in everyday life.

What exactly is a hybrid turbocharger?

A hybrid turbo is an upgraded turbocharger, created by combining parts from different kits to enhance engine performance and efficiency. Unlike standard models, a hybrid turbo consists of the original housing with modified core from other compressors. Modifications may include the installation of a larger compressor wheel, replacing the turbine wheel with a more efficient one, or reinforcing the shaft to withstand higher loads.

The design of a hybrid turbocharger is carefully thought out, which is why this technology is seen as a way to improve system performance without the need for drastic changes to the unit. Often, turbo tuning doesn’t even require adjustments to oil or coolant lines, simplifying the installation process—everything fits into place with the "bolt-on" principle.

What does a hybrid turbo mean for many users?

It’s a common practice that helps drivers get more from their car than is possible under standard conditions. If the upgrade is done by a specialist, you have every chance to achieve the following results:

1. Saving money — installing a hybrid turbo costs less than buying a new original one.
2. Increasing power — this is one of the permitted ways to tune the engine to individual speed and dynamics requirements.
3. Simple upgrade — the ability to modernize the car without complex modifications.

Moreover, turbo tuning using hybrid technologies often allows you to pass vehicle inspections (MOT certificate) in many countries. This means you can legally drive your car on public roads, even with a sport catalytic converter and modified characteristics.

Stages of turbo tuning

The degree of turbocharger tuning can be described using the term "Stage," where each stage represents specific modifications to the turbocharger’s design. Progressing to the next stage is only possible after implementing all the changes from the previous stage. This means you can’t jump straight to Stage 3 without completing Stages 1 and 2.

These stage designations were created to systematize the process of turbocharged engine upgrades. The stage number allows car enthusiasts to understand what changes have already been made and what still lies ahead to achieve the desired effect.

When did this concept appear?

The concept of "Stage" for turbochargers likely came from the Need for Speed video game series. In these games, players upgraded their cars by going through different tuning stages, labelled as Stage 1, Stage 2, and so on. Thus, the game concept transitioned into real life, allowing enthusiasts to organize the tuning process and know exactly what modifications can be implemented at each stage.

What’s the difference between the stages in turbo tuning?

A hybrid turbo can be used for both diesel and gasoline engines, but the modification methods for these systems differ significantly from naturally aspirated engines. There’s a notion that all modifications can be categorized into the first three stages, while later stages are more cosmetic. Let’s take a closer look at Stages 1 through 3 to make informed conclusions.

Stage 1

This is the initial stage of turbocharger tuning, where minimal changes are made to the design. At this stage, an upgraded turbo with an improved compressor wheel is installed, increasing boost efficiency. Additionally, the air filter may be replaced with a zero-resistance filter, and a straight-through muffler may be installed to enhance the exhaust system. Essentially, at this stage, only engine control software is adjusted. No changes to the turbo housing or engine are allowed. As a result, the vehicle’s power increases moderately, and acceleration dynamics improve without significant risk to engine integrity.

Stage 2

This stage allows for more substantial modifications aimed at significantly improving performance. Here, hybrid turbos may be fitted with parts from different models to achieve the desired productivity. Additionally, the fuel system is enhanced, with more powerful injectors and fuel pumps installed. Exhaust manifold modifications are also permitted. Professional tuning is crucial at this stage. Stage 2 enables a significant increase in power and torque, which is noticeable in the vehicle’s dynamics and speed.

Stage 3

Technically, this is the highest level of turbo tuning, where there are virtually no restrictions on modifications. At this point, the hybrid turbo system gains the ability to adjust boost parameters for maximum performance. Engine components may be replaced with reinforced ones, such as:

1. Pistons
2. Connecting rods
3. Valves.

However, such changes require meticulous tuning and may reduce engine lifespan if not properly handled. Stage 3 provides maximum power increase, turning a regular car into a high-performance vehicle suitable for track racing, which is exactly what we did in 1 of our projects when preparing for RWYB at Santa Pod Raceway during Dragstalgia in 2017.

Other stages

Some also highlight Stage 0, which represents the absence of any modifications and corresponds to the factory settings of the car. Later stages, such as Stage 4 and Stage 5, are extreme turbo tuning levels, not intended for everyday vehicles. Cars at these stages are not street-legal due to safety and emissions regulations, but they are commonly used in racing.

Advantages of hybrid turbochargers

The main advantage of a hybrid turbo is the ability to increase the compressor's potential at a lower cost than buying a new one. For example, replacing a standard journal bearing with a double ceramic ball bearing with a bronze separator reduces friction and improves turbo efficiency. Such modifications enhance endurance under high loads and temperatures, while also slightly boosting engine power. It's no surprise that hybrid turbos have been used to set world records in motorsports.

The risks of using modified turbos

Unfortunately, hybrid turbochargers don't always guarantee the expected power increase and, in some cases, can even cause severe engine damage. Additionally, service centres rarely offer solid warranties for their work, which complicates the situation. Moreover, a modified turbo often requires further changes to related systems, such as fuel, braking, and cooling systems, which not only raises maintenance costs but also complicates the tuning process.

Sports or hybrid turbo?

When choosing between a sports and a hybrid turbo, it's essential to consider your vehicle's goals and specifications. A sports turbo is designed for maximum power increase and is suitable for racing conditions, but it requires significant engine modifications. A hybrid turbo combines the benefits of standard and sports turbos, providing a performance boost without major structural changes. Thus, a hybrid turbo may be the optimal choice for those looking to increase their car’s power for daily use. 

Is it worth installing a hybrid turbocharger?

In conclusion, installing a hybrid turbo doesn't always reduce costs, as the price of parts and labor may exceed that of an original part. Additionally, increased weight and improper balance can negatively affect the car's dynamics. The only clear advantage is the power boost, and it's crucial to find a specialist who can justify the investment. This technology is often applied to cars from Volkswagen and BMW, especially models with IS20, K04, 1.4 TSI, M57, and N54 engines. Additionally, such modifications are popular among Audi, Ford, and other European brands. However, before deciding to install a hybrid turbo, it's important to weigh all the pros and cons and consult experts.