A turbocharger is a pump increasing air-pressure before the air goes to the cylinders of an internal combustion engine. A turbocharger consists of two sides: a turbine and a compressor. The turbine is propelled by the exhaust gases from the exhaust manifold, using this energy to drive the compressor on the inlet manifold.
The pressure in a waste-gate controlled turbo is determined by (partially) opening the waste-gate, this prevents the turbo from generating too much pressure or over spooling. The variable geometry turbocharger is also known as VNT (Variable Nozzle Turbo) or VGT (Variable Geometry Turbo). Herewith small blades are placed around the inlet of the turbo. The blades are controlled by a vacuum or ECU operated actuator. The blades close at low speeds thus narrowing the housing, causing the pressure to increase rapidly, resulting in more low-end torque. At a higher speed, the blades open enlarging the housing, which results in more torque at a higher speed. In modern diesel engines, these types of turbos are more and more combined in a Bi-turbo or even Tri-turbo setup. Often we find turbos on diesel engines that are defective because of a layer of soot in the turbo. The cause is often a problem with the EGR system or the (unit) injectors. The layer of soot can jam the turbo, block the waste gate or the variable geometry mechanism gets stuck. In addition, if the turbo is not properly lubricated because of the wrong type, bad quality or old oil it can jam too.
- Insufficient lubrication due to poor quality or old oil
- Aging (wear)
- Mechanical failure
- Electronic defect
- Blocked variable geometry mechanism
- Jammed wastegate
- EGR problems (contamination)
- DPF problems (too much backpressure)
- Faulty assembly
KCPerformance can recondition or replace your defective turbo. We can advise which turbo configuration best fits your needs and supply accordingly. Possibilities are endless; mount a new standard turbo, modify an existing turbo or design and construct a new turbo setup from scratch.
When using a custom turbo, one can choose a hybrid or a complete new, larger turbo. A hybrid turbocharger is designed and built using parts from different types of turbos or even custom parts. By changing compressor/turbine wheel size but also changing materials or bearings this gives us an endless range of flexible solutions, designed to match our customers demands on performance and durability.
If we choose to mount a bigger turbo, there are also possibilities to tailor the manifold, intercooler, downpipe and software to match your requirements. Our expertise ranges from classical to the most advanced, variable geometry and twin-scroll turbochargers.
Older non-turbocharged diesel engines, can be converted to a turbocharged engine with one or more turbos. Any additional technologies commonly used on turbocharged engines can be developed accordingly, for example intercoolers, downpipes, dump valves, injectors, connecting rods, crank- and camshafts.
Advantages of turbocharger assembly
- Improves performance by 15 to 30%
- Uses the otherwise wasted energy from the exhaust gases
- Turbo engines are smaller than naturally aspirated engines of the same power
- Engine characteristics can be customized (eg a comfortable and smooth ride or quick and fierce acceleration, or the right in between balance)
- A turbo engine is more silent compared to a naturally aspirated engine of the same power (the turbine side of the turbo has a damping effect on the exhaust noise)