TURBO PARTS Technical Information Brochure www.hoffer-products.com - - PDF document

TURBO PARTS

Technical Information Brochure

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As the number of modern turbo diesel vehicles in circulation grows and manufacturers turn into small turbocharged gasoline engines, the so-called DOWNSIZING, the use of TURBO is more and more frequent. As the cost to replace a damaged turbocharger is rather significant, its repair seems a more reasonable choice. Hoffer offers professionals the best solution available through a new range of products including quality TURBO parts such as Core Assy (Turbo Cartridges), Variable Geometry Nozzle KITS and Turbo gasket Kits.

TURBO introduction

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Now available…

Core Assy

The Core Assy is the heart of the turbocharger and it consists of:

• the turbine’s impeller
• the compressor’s impeller
• the center housing/hub

The center housing surrounds the shaft and the bearings. Oil from the engine or coolant (in case of a water cooled turbocharger) passes through it. In the company’s range one can find the corresponding CORE ASSY for most modern applications, for both diesel and gasoline engines.

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Our Turbo Parts Catalogue is now available in PDF.

The variable geometry nozzles are used to maintain the turbocharger’s efficiency at the highest possible rate for the entire engine’s operating range. Mainly, the variable geometry turbo is used in the modern turbo diesel engines. Turbocharged gasoline engines are not equipped with a variable geometry turbo (with some exceptions, like the 997 Porsche turbo). The conventional materials that are used cannot withstand the excessively high temperatures of a gasoline engine exhaust gases whereas they can cope with the lower temperature of diesel engines exhaust gases.

60703

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Variable Geometry Turbo (VNT)

1) Low rpm - closed vanes 2) High rpm -

• pen vanes

VNT ΚIT available by HOFFER

• Each ΚΙΤ contains the mechanism, the vanes and the appropriate screws and

rings. Gasket sets for turbocharger repair… Gasket sets like the one illustrated, contain exhaust manifold gaskets, turbine gasket and oil tube gaskets.

VNT ΚΙΤ

1 2

Foreign objects Foreign objects that may enter the air induction system or the exhaust system can reach the turbine and damage the impeller and the VNT vanes. Lack of lubrication Poor quality lubricants, false gasket installation and blocking of the oil tube, are the main reasons for excessive wear or failure of the shaft and bearings. By switching the engine off right after a rapid acceleration, we interrupt the oil flow to the turbocharger, while the shaft still rotates at high speed. This practice can cause excessive wear to the shaft and bearings. Oil contamination The accumulation of carbon or metal particles in the lubricant, created by poor maintenance of the engine, will cause excessive wear to the turbo’s shaft and bearings. High rotation speed and temperature Rotation of the shaft and turbocharger impellers at high speed and high operating temperatures outside manufacturer specification limits, may cause the destruction of the turbocharger.

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Turbo problems and their causes

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How to identify a turbocharger

All turbochargers have a numeric or alphanumeric code, usually on a label or stamped on the compressors housing. The turbo code (red frame in the photo) is all that is needed for the identification. Alternatively, you can use the original code (OE). You can find below some explanatory photos of various types that may be useful for correct identification:

What to check before the installation: Before mounting the new Core Assy, you must identify and eliminate the breakdown causes of the previous turbo. CAUTION Non-compliance with these instructions can cause the turbo breaking down and warranty cancellation.

STEP 1 BEFORE ASSEMBLING THE TURBOSUPERCHARGER

The following equipment inspections and checks for correct conditions and cleaning must be carried out:

• Engine intake equipment:

air filter, intake duct, mass air flow meter, intake manifold, etc.

• Engine delivery equipment:

delivery duct, intercooler, EGR recirculation circuit, etc.

• Engine exhaust equipment:

exhaust manifold, pipes, catalytic converter, muffler, etc.

• Quantity and pressure of the turbo inlet oil:

minimum pressure: 200 kPa (2 bar); remove any obstruction and liquid gaskets from turbo inlet and outlet.

• Oil drain and engine breather pipe:

replace and clean the breather filter to avoid counter-pressure build-up. It is also advisable to repeat this frequently during periodic maintenance.

Core Assy installation instructions

Every Core Assy has been manufactured and tested in compliance with the UNI EN ISO 9001 : 2008 standard guidelines and results to be perfectly interchangeable with the

• riginal part. The operating conditions of the Core Assy installed on the engine have

been carefully simulated during balancing phase, carried out with oil at engine running temperature.

Step 1..

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STEP 2 CORE ASSY MOUNTING

If a Variable-Nozzle Turbine (VNT) mechanism (variable geometry) is present, the following operations must be carried out before passing to STEP 3 (Turbocharger assembling):

• Check for structural and dimensional integrity of VNT mobile vanes. If any

breaking, crack, bending or deformation is present, this mechanism must be replaced.

• Clean carefully the variable geometry mechanism and mount it again,

ensuring that a perfect sliding of the VNT mechanism is provided.

• Carry out the VNT mechanism adjustment and after it, the pneumatic

actuator check.

Core Assy installation instructions

Step 2..

STEP 3 VARIABLE GEOMETRY (VNT) ADJUSTMENT

There are two basic VNT mechanism adjustment methods, identify the applicable one and follow its procedure: ADJUSTMENT OF “A-TYPE” VNT MECHANISM

• Insert the old body in the exhaust

carter well cleaned, ensuring that the variable geometry is correctly mounted. Send the VNT command lever over the body against the adjustment grub screw.

Lift up vertically the old central body, taking maximum

care not to move the VNT mechanism, and measure the distance between a mobile vane and the next one. (for instance: 1,5 mm).

Insert the new Core Assy into its carter seat and set the

same value as previously measured between the vanes, by reversing the above procedure steps and screwing the adjustment grub screw of the new Core Assy.

Core Assy installation instructions

Step 3..

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ADJUSTMENT OF “B-TYPE” VNT MECHANISM

Ensure that the variable geometry is correctly mounted.

• Insert the old body in the exhaust carter well cleaned

and fix it by its two locking screws.

Place a centesimal dial gauge on the pin (where the rod of the pneumatic

actuator shall be hooked afterwards) of the mobile command lever over the body, parallel to the adjustment grub screw; preload the dial gauge of about 5 mm, and then set it to zero. Unscrew the 8 mm locking nut of the adjustment grub screw, taking maximum care not to move the dial gauge, and completely unscrew the adjustment grub screw. Detect and note the shifting that has taken place by reading the centesimal dial gauge (for instance: its hand has moved of 1,65 mm). Insert the new Core Assy into the exhaust carter and ensure that unscrewing the adjustment grub screw the vanes reach full closure at “ZERO”, one against the

• ther, or against the rollers, according to the type of employed variable geometry:

11 vanes / 9 vanes.

Core Assy installation instructions

Step 3 continue..

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ADJUSTMENT OF “B-TYPE” VNT MECHANISM two last tasks…

• Once everything has been verified, lock the new

Core Assy into its seat in the exhaust carter, unscrew the adjustment grub screw, and send the command lever to its travel end, towards the adjustment grub screw.

• Place again the centesimal dial gauge and, by screwing

the adjustment grub screw, set the same value as previously measured between the vanes by the dial gauge reading. PNEUMATIC ACTUATOR CHECK Once the variable geometry has been properly adjusted, check the pneumatic actuator.

• Check that the intake carter, is well cleaned and free from any depot material

due to previous rubbings, place it in position and tighten its fixing screws.

• Ensure that the turbine shaft and its compression rotor can turn freely

without any rubbing or obstacle.

Core Assy installation instructions

Step 3 continue..

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STEP 4 TURBOCHARGER ASSEMBLING

Clean carefully the intake ducts and the exhaust manifold because any foreign materials, even small, that are allowed to enter it, damage the turbocharger. Replacement of the inlet pipe is always strongly recommended; the outlet pipe has to be checked for absence of obstructions and bending. Before mounting the turbocharger, verify that the oil is reaching the turbo. This can be checked by making the engine turn a moment without completing the engine start, and keeping the oil delivery pipe detached in order to make the residual dirty oil and small slags flow into a suitable drain tray and not inside the turbo. Assembly the turbocharger and fill it all up with new, clean engine oil. Start the engine and let it run at idle for 5 minutes, checking that no leakages come out and avoiding sudden accelerations while the engine is cold. Never switch off the engine soon after an acceleration, because the oil pump stops immediately while the turbosupercharger shaft still continues to run for a while and, turning without oil, the turbo is damaged.

*VNT = Variable Nozzle Turbine

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Core Assy installation instructions

Βήμα 4..

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Repairing your turbocharger, besides being a much cheaper solution compared to its replacement, has less of a negative impact to the environment as it uses less raw materials.

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Thank you for choosing HOFFER!