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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. " R# j6 \* z% t# U8 O3 n) R
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Tech Sheet
1 r* K5 T) d5 G1 H% i‘Frequently Asked’; [% D0 d' X. M+ }* g
‘Turbo Questions’(In no particular order)7 l- u. g. G7 X+ h. a% @& G4 T
Your turbocharger is engineered to match the specific requirements of the engine it is# J, o9 F4 Z9 ^2 W9 x( G+ I
fitted to. Each is dependent on the other to maintain optimum performance. Don't& `" Y! k \/ @
think of the turbo as a bolt-on accessory, rather as an integral part of the engine. The9 N' A. _" @; }3 @
turbo's requirements are similar to the engine’s. It is, therefore, essential that/ N: ^, U/ d: b& o5 c, T
scheduled servicing, using good quality oils and parts, is central to caring for your' W$ B, h. j5 ]/ m6 p# ~
turbo.1 n' @/ q+ q9 y5 W: m
In many instances Berrima Diesel receive turbochargers which have been$ S0 i- [6 F# y4 k/ i& L
misdiagnosed as having a turbo problem, when actually the turbo is not at fault.
$ j9 }& R. c8 Z: mIncorrect fault finding is often caused by a lack of product knowledge. Many
; M6 ~, G0 f" y; T2 l8 V' @5 G" `contributory items around the engine bay can trick the unsuspecting into believing the; ~3 b6 `' } {6 t
turbo is the culprit, when in fact it is not. Unfortunately, if the real problem is not$ g) c: N2 d0 P C
diagnosed before a replacement turbocharger is fitted, the problem still exists!
2 N& |0 ?( V- v+ _7 T9 T5 i5 O5 OWe have a saying at Berrima Diesel which goes, "Turbos don't die. They’re killed". A
3 [1 k0 w6 B/ s0 u' a4 cturbo can be killed in many ways.
+ `; N& Q9 H1 O2 m% |' b0 N w7 xForeign object damage results in either the air intake "compressor wheel" or exhaust
4 H, k* W/ Z" a. m"turbine" wheel being damaged. The former is often caused by someone accidentally# p) r- q0 }. ?0 a" f
leaving a nut or other foreign body in the air induction hoses. Please be extremely$ D# h" _. h" g" W, E& m
careful if going to an aftermarket air-filter. Genuine is bests there! In the latter case,& S ~7 z! u* U$ F! ?7 r& y
this may be caused by part of an engine component, such as a piece of valve, exiting
1 S' t P2 q1 ]" {2 ~$ ~9 R! M! S2 Cthe engine in rather a hurry! In both cases it results in severe turbocharger damage# c6 x4 D3 t1 q5 [$ b
instantly.9 q8 Z+ t0 x# g1 \
Turbochargers are simple in operation, but manufactured to precise tolerances as fine& r: ^8 T5 I6 h
as 1/ 1,000,000 of an inch. The turbo unit manufacturers balance and test every single
) \( @" T- N0 C+ `* O" a$ |turbocharger many times, including final assembly. The balancing methods and
+ y1 M, }1 x, R! F; aprocedures are unique. Without them, no turbocharger can be balanced to the ultrafine# I) k1 |/ ?: H! N* W
tolerances required for today’s high speed turbos. It is now common for& r5 y0 L7 e" f# |" s7 p5 K
turbochargers to spin up to 150,000 rpm +.( B8 a( c- I5 |$ g# j% t2 K
That’s approximately 35 times faster than most diesel engines rev at the red line!
7 k" v/ H3 \+ x% r! a) T* q v, VSophisticated machinery and highly trained factory staff ensure that the highest
8 K. @: i& I$ Mstandards are always maintained.# L: m* l& l4 s' K' `! s! A) t
Useful tips when driving any turbocharged engine, whether it be petrol or diesel, are
9 W% H5 L; B$ b. l: F4 G/ Fto always allow the engine to warm-up fully, until the water temperature gauge
' v! b* T2 E! d+ Preaches normal, before full throttle is used. Try to plan the end of your journey
% ?3 V) i/ E" Y+ S8 dsympathetically. Don’t use full throttle or allow the engine to labour during the last
& u" C7 `7 s. Q4 S/ z7 Jfew miles. This will prevent excessive heat build-up within the turbo when the engine
0 ~7 M) z7 _" F [* [is turned off. Also, when coming to a standstill, try to leave the engine idling for a' H6 x" ~, x, y0 [" V
few extra seconds to allow the heat to decrease. No need for a timer though, just undo: }7 e0 f! H; i' y- z+ c2 k4 O% i
your seat belt first and then turn off the engine. Never rev the engine just as the
; M+ H9 A+ U6 i9 w, {& ~ i8 dignition is turned off. Remember the turbo spins at a far greater speed then the
6 `, S& Z/ E' d( `6 Qengine, but is lubricated with engine oil. Once the engine stops the oil supply ceases
0 Y+ X' _2 d! ], j+ }5 F% twithin a few seconds. In reality, none of the above traits will cause a turbocharger to
; K; q l# h2 ?7 ]; ifail immediately, but repeatedly over a long period, they could reduce the life of your
5 z( o: ]7 z* Z8 cturbocharger./ b O* R: u7 [4 a' n _) R
If it becomes necessary to seek advice about a turbocharger or a turbo related6 N3 o9 e8 F0 f9 S8 G- i
problem, always rely on a professional. Berrima Diesel, together with DTS
% F! }- Y) T; _& D3 Wturbochargers, are Australia’s leading turbo specialist, and are acknowledged as one; Z& i* D* G6 H8 l
of the most experienced turbo installation companies in the world. We can advise0 `. [' Y4 T! }: K* C8 ^( P& Z
customers with turbocharged 4WD’s on a wide variety of questions and issues7 o8 {7 `1 S; G' a
relating to owning and running a turbo car.' |* ~9 w0 I0 F q
It cannot be stressed too much how important it is, when purchasing turbocharger
) g" ^/ Y8 Y7 U4 K9 Qsystem, always to choose the top brand name -Berrima Diesel. Consider this. As with
! i8 X( r9 v& `" ?/ Qso many things in life, quality costs, and there are sometimes cheaper turbos for sale.
9 N1 ~4 [ |( O: i4 qWithout the safeguard of using a Berrima Diesel turbocharger, you run a serious risk) e1 a6 w7 ~4 ^# b5 W- q! L
that your short-term saving may turn out to be a long-term nightmare.! g6 c' w% I* \. }% g4 ]# l
What is 'Boost'?$ u3 F% I6 `$ m: V0 M
Boost is a term used to describe the increase in pressure, provided by the
, R8 I5 _+ h \' c6 cturbocharger, to the volume of air, entering the engine. This pressure is expressed in9 Y! A3 L/ q; `1 m, O) d
a number of different units, (BAR, ATM, Kpa, P.S.I.), but they all mean the same. v& j* C7 U' l, L
thing. For purposes of approximate comparison; 1 BAR = 1 ATM = 100 Kpa
6 ^9 e$ p. r8 v) _/ [' Z9 ]14.7P.S.1. When the pressure of the engine's inlet air is increased, the engine's power
/ E* b. s3 R% f6 @) P6 t9 g+ @output is increased. This pressure increase is called 'boost'.
z' r& H0 G: X2 w1 F5 PHow does fitting a Dynamic Turbosystem effect the power of my
' ]0 s! W7 A% u. `2 A5 nvehicle?+ Q. D# Y2 k; _! V
Modern 4WD diesel engines, typically produce peak torque (pulling power), at
' l, b& E: z' w3 M. @ _- Waround 2,000-2,500 R.P.M. and peak horsepower at around 3,500-4,000 R.P.M.; v% j" Z. D+ S4 i$ z; W
Turbo boost starts at approximately 750 R.P.M. and rises progressively to its" [$ @2 ?' N3 r
maximum pressure of approx. 70 Kpa (10 P.S.I.) by approx. 2,000 R.P.M. At this
% Y- Y2 S% T& A8 fpoint, the percentage torque increase of a correctly tuned installation is approx. 40%,
' n1 _ {& k; ?7 Y# X- Uat the wheels. This continues to the peak horsepower point of 3,500-4,000 R.P.M. At5 B- |" \3 B. }# y9 y
no point is it ever any less than standard. e.g. at 1500 R.P.M. it is at least 25% greater
6 m; |! I9 k: b. v. z- Fthan the standard vehicle at the same R.P.M.7 z) z& _/ n$ ?5 s- `2 m
Can I fit a Dynamic Turbosystem myself and, if not, how long and: }0 W3 r% q0 B$ q
what is the cost of having it fitted for me ?
& P9 }* ?1 D( y( d, L% p/ s& o8 KWhile most competent mechanics could probably fit a Dynamic Turbosystem,. x x5 v$ _( R9 p8 A
tuning requires specialised knowledge. The lack of this knowledge could have& g- j; h z5 `! t9 c" y( y5 O
serious consequences. In addition, warranty can only be provided on Dynamic5 B/ L! Q1 a' h G2 ]" X& m
Turbosystems which are installed by authorised facilities.# L- G, R+ w% T7 O, c
The cost of having the installation performed by Andrew at Berrima Diesel is
8 ^6 e* A2 ?3 ~/ E4 B9 f7 l% x8 Z4 bonly about 10% of the total purchase price. This provides a warranted, correctly. ]$ j7 t+ E7 V
tuned, "no hassle" installation for the customer. All diesel vehicle installation can be
* ]2 d6 q% T9 W2 N+ jperformed in one day.1 W1 e4 x1 S9 S( r; w; q/ W
What creates the most heat? Fuel or turbo boost?% ]2 L! B$ t* Z5 O! \
Diesels do not need an air control (eg. manifold butterfly valve. The only ones( \) [: d% \! u% ?
requiring a butterfly are vacuum operated governor pumps) to operate. The more air
5 P# w0 O" J0 O9 z2 X J# M0 ?& o" jthe better. Add too much fuel to the equation and the exhaust gas temperature. k, r) K" z/ U+ a( I1 p
rises rapidly.2 i; [/ K& z# j( _7 D0 ^
What type of oil and how often should it be changed ?/ R9 J1 ^$ F" ]* p3 R; U
Turbos must have good quality oil. Use either a mineral, semi or fully-synthetic" [4 e- _# p- Z; ~. q* a" I2 v% V
engine oil. Berrima Diesel recommends Shell Rimula range or Shell Helix Ultra .( K7 C0 H1 r/ b& Y7 X! o
Change oil at intervals recommended by the vehicle manufacturer.1 k( C# N1 O$ I) `/ }" `0 p
How long does a turbo last ?
# _8 \1 j4 _1 e. t, OOn average, as long as the engine or longer with regular engine servicing and good. X1 i1 Q. F: U( o: c, A& O
quality engine oil.- b& T# r- L6 E( W! ^" E# \
What is a ‘dump’ valve or ‘blow-off‘ valve ?- @$ |: s; V+ p( ?4 A8 p# z
A valve which relieves boost-pressure between the compressor outlet and engine as
8 A) [" i3 ^( y1 A. _" u/ |the throttle is closed (Only required on throttle valve controlled diesels which are
5 o U% }. s+ w; C* Q1 ?5 |4 Hrarely seen these days). These are commonly fitted to hotted up petrol cars so it
1 M( z# {* j* _sounds good changing gears among other reasons!
7 @3 p8 L) o, BCan I fit a turbo from another 4WD ?
7 _+ O P" U) xNo, virtually all turbocharger are different inside, even if they appear similar on the
% A/ l$ M( B1 s4 c. v4 Q" D2 M2 Loutside. The turbo model e.g. Mitsubishi TD04, is only the model, not the
% A, A$ q) M- k! E+ [6 n- A* tspecification.
' A- p; _6 o9 j, W" @1 \; @1 aShould I leave my engine ‘ticking over’ before it is turned off ?
, y2 R4 ~: V5 Q% ~0 N! ]Not for normal every day driving, but still worthwhile if the engine has been under* D2 e$ y+ G$ |: X! D5 o
load or raced before being turned off. e.g. Towing a caravan or after climbing a long
4 S! v& E. s# B! Lincline.
. T+ a: l% k: H6 }( N% n5 i5 }" y2 n9 kWhy is it important to balance a turbocharger ?. A* E3 K0 m1 O* w4 {
Without highly accurate balancing, vibration will create a whining noise, reduce
3 ?! V) w/ l9 K! H7 Y; hturbo bearing life and reduce turbo efficiency.
+ @* H4 @ v' l. r# h1 eHow much boost does my turbo produce?
: P# X: o; Q$ z5 z1 OCorrectly set up diesel 4WD turbochargers run up to between 10 PSI to12 PSI with& B( y; L2 m' w G2 z d, j& W/ K. r* \
Intercooler turbocharged engines running upwards of 13PSI.5 v7 ]5 @, {1 M1 M( T$ S
How many psi in one bar ?
/ w" y5 M1 ~5 i$ a7 O14.7 psi = 1 bar.
6 s/ S6 w1 f4 z4 Y: EAre all actuators the same ?
: S5 v+ I S3 b% A- N. zNo, each has a different opening pressure and rate.
% ` O7 P" A9 D. A( h) M, UOil in the turbo inlet pipe - Should I be concerned ?* q! C- r: U, u: Q- m
A small amount of oil usually exists, drawn in from the engine's crankcase breather& [0 J$ [. `% E9 @( c8 T
system. High engine wear will increase the amount of oil found, and will require: g) J+ y* K5 m; i W2 x
further engine tests (not turbo).; m; W' s1 S8 y0 r, S4 f
Should a turbo be serviced ?. M! {( R' X8 Y: j" C/ @5 C
No specific turbo servicing is required, but regular quality engine servicing is needed8 `/ p4 r1 m1 L- D$ J
to reduce the chance of turbocharger problems.
8 ]; ~- o N5 s ?! KWhat is a water-cooled turbo ?
( {' s; t: I: C; kThe central part of the turbo, housing the bearings, is surrounded by a water jacket
# Y! V/ d" c# y# f9 P/ s! a, j$ ythrough which the engine's water coolant is passed. This water continues to circulate. C1 Y1 W- K& E. G6 G2 @1 q
after the engine is turned off, cooling the turbo, and preventing heat soak.8 l: b: R K3 x9 X1 C
Do I need to up grade my exhaust ?6 i! w2 b4 {/ I$ h# Z
Generally not. Our systems are designed to run utilising as much genuine component
: X' V+ D8 @3 m, L8 Cas possible. Some systems on the market promote exhaust change as it is required by/ f+ }8 ]8 D) `' R7 v
that particular turbo. Doing so usually picks up more noise than performance.# F; E. a% N q" b2 E" z
How noisy should a turbo be ?% [1 Y+ L# C/ y# f( _7 s, F+ h6 s
Only an unbalanced, worn out or damaged turbo will produce any significant turbo
* K1 v# h+ c) ]) H, Rnoise.
4 k) Z5 q! N. C. b% [/ KWhat is an intercooler ?0 ~( a% U1 Y' j r
A special type of radiator which cools air before it enters the engine. As a turbo
) P+ ?5 R2 B! L" kcompresses air, the air heats up. Power can be increased if the air entering the engine
. i: |% l _/ Z9 U# q4 T! Uis cooler. The cooler air is more dense meaning that more fuel can be injected for9 o3 i: }' w, z6 F# e8 b* r
more power.
2 v. r3 X! h$ ~' DWill my vehicle run ‘cooler’ with an intercooler ?
! c$ r* q# o/ f" e' ZTheoretically, but not always the case! We commonly find Intercooled 4WD vehicles, k2 d+ f) T8 B! ^
running hot due to over-fuelling and radiator restriction. Restriction meaning that hot# A) S! V' ^; u0 H4 t
air passes out of the Intercooler over the air conditioning condenser and finally the0 f/ G6 {% Y+ Q8 s9 y' H, k
radiator. The poor old radiator is left with scraps of extremely hot air and then is
5 c2 E! ^# _! o7 g, M8 y Wexpected to cool the engine. We don’t advise fitting them as hot Australian conditions6 [* I" h3 j: H! `" W8 j
can often be the catalyst for engine heat problems.
, m7 o! j) u6 B/ Q( IWhat will happen to my fuel consumption?: o* H% K; O* Q( K4 t; u+ H
More power generally means more fuel. With a diesel turbo system, fuel consumption
2 Q i" e5 R# t" W- a8 q& z- R5 Mstays generally the same and can become better under towing conditions |
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