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NO SPEAKING, LAITY
This is my first time to address here. XIAO FENG CAN YUE wants me to tell guys how to drive a turbo car correctly so that everybody can benefit it and identify who is correct and who is a laity but which made so much boring noise. Please see the attachment that tells you how to deal with a TURBO. Do pay attention to BOOST R.M.P, PEAK TOUQUE R.M.P, and PEAK HORSEPOWER R.M.P. 4 n J5 p- S, J) u# I+ J3 ` U
/ c9 O5 p, s; [ ]( F; E" C' S0 q$ C7 v T! n
Tech Sheet' {* w5 y" u% H' ?- n
‘Frequently Asked’0 R+ L. P7 z6 `% x
‘Turbo Questions’(In no particular order)9 ]( X1 z& }. Y& Y
Your turbocharger is engineered to match the specific requirements of the engine it is( ]( ` l4 V& A5 z) @
fitted to. Each is dependent on the other to maintain optimum performance. Don't
+ g& n0 d& x) Q& m' ~5 `think of the turbo as a bolt-on accessory, rather as an integral part of the engine. The
* m. L, H: v' v: E; aturbo's requirements are similar to the engine’s. It is, therefore, essential that
; d, U- d& M! x4 r& ^* Jscheduled servicing, using good quality oils and parts, is central to caring for your
% l. M& l' f! K. G& L$ q6 \1 dturbo.
0 \) N- m4 E, u7 L- E( ~In many instances Berrima Diesel receive turbochargers which have been
& m0 Q$ E+ p/ ?6 A7 K: ?misdiagnosed as having a turbo problem, when actually the turbo is not at fault.
: b; u: f5 v- h) _- N8 \, tIncorrect fault finding is often caused by a lack of product knowledge. Many
, { y \: @; Y& icontributory items around the engine bay can trick the unsuspecting into believing the( i5 F2 X7 {) [4 c+ ^' S/ B, X
turbo is the culprit, when in fact it is not. Unfortunately, if the real problem is not
7 D, `$ x! r& Z sdiagnosed before a replacement turbocharger is fitted, the problem still exists!
0 |8 Z4 A* `' V8 a/ fWe have a saying at Berrima Diesel which goes, "Turbos don't die. They’re killed". A
/ m6 Y5 z5 B6 E3 f2 _6 J8 Q& r; M3 y. _turbo can be killed in many ways.
5 j( s4 t+ u2 A! U1 H: ]! iForeign object damage results in either the air intake "compressor wheel" or exhaust
* q( W, w! o: k% a& `"turbine" wheel being damaged. The former is often caused by someone accidentally
+ P0 n& ?4 P; \5 `% t/ Yleaving a nut or other foreign body in the air induction hoses. Please be extremely
3 G4 L4 \. U8 Z* T/ B' Ucareful if going to an aftermarket air-filter. Genuine is bests there! In the latter case,
" _' b1 b, Q! Y3 f0 vthis may be caused by part of an engine component, such as a piece of valve, exiting/ M) w4 F$ \5 f$ y# u1 N
the engine in rather a hurry! In both cases it results in severe turbocharger damage
7 `( u& X3 W) {" e. u dinstantly.
+ ]/ L5 s2 Q3 L8 U5 A4 V: |- T- C% t1 d! HTurbochargers are simple in operation, but manufactured to precise tolerances as fine/ A; L# ^$ V" ]4 t3 N9 j! e8 X
as 1/ 1,000,000 of an inch. The turbo unit manufacturers balance and test every single
- V E+ N+ ?2 L$ cturbocharger many times, including final assembly. The balancing methods and
9 Q! U' ?" \. C- a. dprocedures are unique. Without them, no turbocharger can be balanced to the ultrafine
7 Y5 ]! J) _7 R i7 Rtolerances required for today’s high speed turbos. It is now common for' u+ v5 j& f k0 F4 f/ q8 r7 Y
turbochargers to spin up to 150,000 rpm +.
; F: Q8 I, G4 mThat’s approximately 35 times faster than most diesel engines rev at the red line!+ v. h7 K7 }$ ~6 }
Sophisticated machinery and highly trained factory staff ensure that the highest% C& [ s; Q2 d2 q
standards are always maintained.
" j; d( U4 {$ e$ F( tUseful tips when driving any turbocharged engine, whether it be petrol or diesel, are
' \; h1 B& c2 P$ {to always allow the engine to warm-up fully, until the water temperature gauge$ [5 g( k! U5 l# p
reaches normal, before full throttle is used. Try to plan the end of your journey: r c, {; G9 }! j' h) Y
sympathetically. Don’t use full throttle or allow the engine to labour during the last& K5 C+ V, U6 G# `9 J
few miles. This will prevent excessive heat build-up within the turbo when the engine6 D3 H) d, Q( o4 _5 t
is turned off. Also, when coming to a standstill, try to leave the engine idling for a ?6 n2 d% V& B& j
few extra seconds to allow the heat to decrease. No need for a timer though, just undo5 H, [( ?; }) f: ^1 J3 ?' l
your seat belt first and then turn off the engine. Never rev the engine just as the% a: f' \4 t& |! k; J; G% r* N
ignition is turned off. Remember the turbo spins at a far greater speed then the% M4 n- [: h6 U5 o
engine, but is lubricated with engine oil. Once the engine stops the oil supply ceases2 U$ C D6 Y" _5 O
within a few seconds. In reality, none of the above traits will cause a turbocharger to3 R- c# S/ t. Q8 g9 h
fail immediately, but repeatedly over a long period, they could reduce the life of your
0 n4 p! U" I+ Z3 d& r3 K iturbocharger.0 Z9 V ]7 g8 E4 D, s. a
If it becomes necessary to seek advice about a turbocharger or a turbo related
7 }+ v. s3 G' u3 J0 E; t" yproblem, always rely on a professional. Berrima Diesel, together with DTS! |0 F0 e% s6 a. V$ g& j
turbochargers, are Australia’s leading turbo specialist, and are acknowledged as one
0 I5 k6 U% m6 z. {of the most experienced turbo installation companies in the world. We can advise% ^; W2 @% Y; F* H/ m/ P) e k' _
customers with turbocharged 4WD’s on a wide variety of questions and issues
/ r* c0 c/ p$ j1 b3 E+ Wrelating to owning and running a turbo car.
- n8 S% U0 q; N/ d% E- sIt cannot be stressed too much how important it is, when purchasing turbocharger. r& K# j* v' l Z) i. G
system, always to choose the top brand name -Berrima Diesel. Consider this. As with$ q2 Y( L z# w; s
so many things in life, quality costs, and there are sometimes cheaper turbos for sale.
3 U; B; i# |7 g. b& Y; p6 g+ uWithout the safeguard of using a Berrima Diesel turbocharger, you run a serious risk
6 ]& y1 f( K0 r0 Athat your short-term saving may turn out to be a long-term nightmare.& p( w- @9 K1 b
What is 'Boost'?
. M3 _0 ?3 X& dBoost is a term used to describe the increase in pressure, provided by the
! d, O/ R6 c: ~; s1 I# P/ rturbocharger, to the volume of air, entering the engine. This pressure is expressed in
, d) N/ u" p. h/ e; z& ta number of different units, (BAR, ATM, Kpa, P.S.I.), but they all mean the same3 z k. V9 w; B, m
thing. For purposes of approximate comparison; 1 BAR = 1 ATM = 100 Kpa- V: o! e4 R8 A& {2 P
14.7P.S.1. When the pressure of the engine's inlet air is increased, the engine's power- f# o* \9 }# o. D6 `
output is increased. This pressure increase is called 'boost'.7 h$ K* D7 {: M$ F. I- m
How does fitting a Dynamic Turbosystem effect the power of my
# X( K; U- s/ O. O- k" a. Rvehicle?! v* a) E+ X' ~7 j$ I
Modern 4WD diesel engines, typically produce peak torque (pulling power), at. `+ w9 i7 c1 j) s$ ~
around 2,000-2,500 R.P.M. and peak horsepower at around 3,500-4,000 R.P.M.) ~( p D: ]% J2 A8 x
Turbo boost starts at approximately 750 R.P.M. and rises progressively to its
\! o0 a4 r" P* P% g3 c& qmaximum pressure of approx. 70 Kpa (10 P.S.I.) by approx. 2,000 R.P.M. At this
$ w" w5 V4 J; \1 l8 Wpoint, the percentage torque increase of a correctly tuned installation is approx. 40%,: M1 S2 r- k* A7 e) u- p+ u
at the wheels. This continues to the peak horsepower point of 3,500-4,000 R.P.M. At( z: o. g; o! e! P3 R2 B( p
no point is it ever any less than standard. e.g. at 1500 R.P.M. it is at least 25% greater
( r* j7 q7 V# \: Y5 {& Gthan the standard vehicle at the same R.P.M.
% Z; `$ x" |/ m9 g& fCan I fit a Dynamic Turbosystem myself and, if not, how long and
+ _4 s6 k/ Q" [' I3 _& }$ Hwhat is the cost of having it fitted for me ?2 n/ d# @. l p% X/ v
While most competent mechanics could probably fit a Dynamic Turbosystem,/ J0 d7 g& }: C5 z5 ^
tuning requires specialised knowledge. The lack of this knowledge could have
# O& h4 b+ R. c2 v; `* |" h7 \, O) i ~+ dserious consequences. In addition, warranty can only be provided on Dynamic% T" H8 p. W |) ~( v' `
Turbosystems which are installed by authorised facilities.1 Q) _, f9 r1 F1 L3 t
The cost of having the installation performed by Andrew at Berrima Diesel is6 i9 [- [6 |8 `+ A0 w1 q0 l2 T
only about 10% of the total purchase price. This provides a warranted, correctly
5 Q, N4 a3 m& n/ Q8 v, atuned, "no hassle" installation for the customer. All diesel vehicle installation can be
# d+ |) F2 E, O3 J! l6 V; iperformed in one day.
! ]& }! ~ w" R+ g& T# N! sWhat creates the most heat? Fuel or turbo boost?
i3 g/ X8 K; w, k8 j+ DDiesels do not need an air control (eg. manifold butterfly valve. The only ones
# U4 u4 W0 F7 Jrequiring a butterfly are vacuum operated governor pumps) to operate. The more air6 z0 g$ y# [# _; A
the better. Add too much fuel to the equation and the exhaust gas temperature
. x+ g' ]- `5 S' R% |: V ?rises rapidly.
4 S E c( b7 C1 U- n4 i& `What type of oil and how often should it be changed ?
" N% T" y# N) j, R0 Q. q6 ~6 V& tTurbos must have good quality oil. Use either a mineral, semi or fully-synthetic, d2 R# `* F! ?6 H0 `: l
engine oil. Berrima Diesel recommends Shell Rimula range or Shell Helix Ultra .! Z9 f8 G! K, V
Change oil at intervals recommended by the vehicle manufacturer.( P- N5 L# q, O: y
How long does a turbo last ?
$ I" b/ p. R6 e; f+ j' uOn average, as long as the engine or longer with regular engine servicing and good; n) P9 M5 {% q; T: F
quality engine oil." ?/ r7 V8 Q. M! s7 ]
What is a ‘dump’ valve or ‘blow-off‘ valve ?
# W4 J6 C7 r3 MA valve which relieves boost-pressure between the compressor outlet and engine as
' C/ c3 {- m3 x5 e! D( X" C+ Qthe throttle is closed (Only required on throttle valve controlled diesels which are
8 L! G1 w9 f' c v9 G$ |0 m: |rarely seen these days). These are commonly fitted to hotted up petrol cars so it* U8 B+ b& n f& |) u- F' J. D4 k
sounds good changing gears among other reasons!
3 v7 p! B6 P" O7 F, OCan I fit a turbo from another 4WD ?
$ z% t6 C; R2 oNo, virtually all turbocharger are different inside, even if they appear similar on the
8 |. l. r7 R' O) u( A) poutside. The turbo model e.g. Mitsubishi TD04, is only the model, not the) R# c* u# ^0 X: B; k, K
specification.
) l m. H/ f Y, mShould I leave my engine ‘ticking over’ before it is turned off ?
% P$ y* K# d7 U2 sNot for normal every day driving, but still worthwhile if the engine has been under
4 q: L( U' }" Y) nload or raced before being turned off. e.g. Towing a caravan or after climbing a long+ `0 e+ X+ k& {/ Z$ k* @" f
incline.9 r7 A7 H9 ]+ t1 z4 j3 |5 |& s
Why is it important to balance a turbocharger ? k$ J* N9 O$ z) f Z% I8 r9 W; N6 Q
Without highly accurate balancing, vibration will create a whining noise, reduce7 D/ ]8 n5 P% @1 V2 p; W
turbo bearing life and reduce turbo efficiency.' R y3 R+ N {5 Z, x* r+ Y
How much boost does my turbo produce?
! g4 K+ B: s& v( GCorrectly set up diesel 4WD turbochargers run up to between 10 PSI to12 PSI with1 E6 x; C+ E% z. E: H, H$ |
Intercooler turbocharged engines running upwards of 13PSI.# C) B( B+ ~" g0 S
How many psi in one bar ?8 n4 M4 K/ ]& @. h: \, B7 i
14.7 psi = 1 bar.# [! O, o4 o9 h% R4 f5 `
Are all actuators the same ?8 a, H0 |- j. B1 _0 o2 N' n
No, each has a different opening pressure and rate.4 w7 I" x5 M* z) i5 N' P2 T
Oil in the turbo inlet pipe - Should I be concerned ?' I2 C+ L# w3 f: p
A small amount of oil usually exists, drawn in from the engine's crankcase breather
# e8 U* B; {" w/ L6 psystem. High engine wear will increase the amount of oil found, and will require8 C% [4 J& G% O5 _) D" V
further engine tests (not turbo).3 B5 Q% Y- K$ d
Should a turbo be serviced ?
6 ]/ @$ v* E" u$ g; s, aNo specific turbo servicing is required, but regular quality engine servicing is needed- V4 I8 p& F. C7 x0 ], b
to reduce the chance of turbocharger problems.& j& F+ c$ U/ z9 }& d
What is a water-cooled turbo ?
0 F( P" H: n% E6 G* l' G- S/ R% k1 rThe central part of the turbo, housing the bearings, is surrounded by a water jacket* R: k! o( `- ~* f
through which the engine's water coolant is passed. This water continues to circulate4 ]7 r& \( w8 j5 ^& V" k$ _7 J8 z
after the engine is turned off, cooling the turbo, and preventing heat soak.
. D7 A4 E0 [; C1 C& L: r( `" L) `Do I need to up grade my exhaust ?( c& |) M; T3 {8 p9 @* U
Generally not. Our systems are designed to run utilising as much genuine component5 Q( [5 ]4 f( I" c
as possible. Some systems on the market promote exhaust change as it is required by; H5 D9 g+ Q2 `4 {* X
that particular turbo. Doing so usually picks up more noise than performance.
0 M, h4 r; v2 j+ nHow noisy should a turbo be ?4 Q! k7 T, p" d
Only an unbalanced, worn out or damaged turbo will produce any significant turbo4 U* ~# s" O7 W8 y
noise.
% X, t/ f$ A) B- C. |What is an intercooler ?
" o( n! t" }' A1 v2 R' [7 n/ y6 iA special type of radiator which cools air before it enters the engine. As a turbo
$ }2 @7 R' K& t, ]" }% d( zcompresses air, the air heats up. Power can be increased if the air entering the engine
, H2 A- T: l# q" g& n( P5 \6 Fis cooler. The cooler air is more dense meaning that more fuel can be injected for+ W) w k7 |0 o/ `* O
more power.8 A$ R# R! e+ |+ j: K M' {
Will my vehicle run ‘cooler’ with an intercooler ?
& u j" |9 a0 p9 v" mTheoretically, but not always the case! We commonly find Intercooled 4WD vehicles
, l$ Q1 g, z# G7 ^" k+ rrunning hot due to over-fuelling and radiator restriction. Restriction meaning that hot" Z( p7 x" x4 D+ T7 g+ N. l
air passes out of the Intercooler over the air conditioning condenser and finally the
& e8 Z6 w8 N+ p8 w, I6 [- U0 O5 L4 uradiator. The poor old radiator is left with scraps of extremely hot air and then is
_/ a+ n3 Z1 B# d4 O1 ]expected to cool the engine. We don’t advise fitting them as hot Australian conditions
4 K* f2 E1 \2 ucan often be the catalyst for engine heat problems.) J/ @4 T, n/ o! }; V
What will happen to my fuel consumption?5 D" b. \. _8 E9 n: a
More power generally means more fuel. With a diesel turbo system, fuel consumption& V6 c+ ~1 ~2 @
stays generally the same and can become better under towing conditions |
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