Universal engine turbocharger

Types of universal engine turbochargers

A universal engine turbocharger transforms a low-displacement engine into a high-performance one. It compresses the air that goes into the cylinders, allowing more air and fuel into the cylinders. As a result, the combustion generates more power without making the engine bigger. The universal engines come in various types of turbochargers.

• Variable geometry turbocharger (VGT)

  The VGT has adjustable blades in the turbine that change position depending on the engine's speed. The new position optimizes the airflow through the turbine. The universal VGTs spin quickly at low engine speeds and eliminate turbo lag. Furthermore, they improve fuel efficiency and reduce NOx emissions. As a result, the VGT is popular in diesel engines.

• Wastegate turbocharger

  The wastegate turbo uses a wastegate valve to control the exhaust flow through the turbine. The valve either closes or opens to regulate the boost pressure. Most manufacturers use the wastegate turbo in petrol engines. The boost from the wastegate turbocharger is linear. As a result, the driver gets a consistent power increase.

• Dual turbo engine

  Some universal engine turbochargers have two turbines. The dual turbochargers are either parallel or sequential. The parallel dual turbo engine has two identical turbines. Each turbine forces air into one cylinder bank. The twin sequential turbos use two different-sized turbines. The first turbine is small and spools up quickly at low RPMs. The second turbine is large and spools up at high RPMs. The twin sequential turbochargers ensure a broad power band.

• Electric turbo-compound (ETC)

  The ETC uses an electric motor to drive the turbine. The motor can also generate electricity and charge the battery. The ETC is ideal for hybrid and electric vehicles. The electric turbo-compound improves low-end torque. It reduces CO2 emissions and boosts overall engine efficiency.

• Variable twin-scroll turbocharger

  The variable twin-scroll turbo combines the VGT and the twin-scroll technologies. The VGT's adjustable vanes optimize the airflow in the universal engine variable twin-scroll turbo. They improve the efficiency and boost of the turbo. The twin-scroll turbocharger has two inlets for the exhaust gases. The separated exhaust pulses reduce turbo lag and improve the turbine's efficiency.

Specification and maintenance of universal engine turbocharger

When sourcing turbochargers, it is important to check the specifications in order to understand the scope of the project. Here are some specifications one should expect to see.

• Compressor Wheel

  Material: Aluminum, titanium, or carbon fiber.

  Diameter: 3 to 7 inches (76 to 178 mm) or more.

  Trim: Low, medium, or high trim.

• Turbine Wheel

  Material: Inconel, stainless steel, or titanium.

  Diameter: 2.5 to 6 inches (64 to 152 mm) or more.

  Trim: Low, medium, or high trim.

• Turbocharger Housing

  Material: Cast iron, aluminum, or ductile iron.

  Compressor housing: 0.2 to 1.5 liters in volume.

  Turbine housing: 0.1 to 0.5 liters in volume.

  Exhaust housing: 0.05 to 0.3 liters in volume.

• Bearings

  Type: Journal bearings, ball bearings, or ceramic bearings.

  Material: Brass, bronze, or ceramic.

  Clearance: 0.001 to 0.005 inches (0.025 to 0.127 mm).

With all these specifications in mind, how does one maintain a universal turbo engine? Here is the maintenance routine that will ensure the turbo lasts.

• Regular oil changes: Always change the oil as recommended by the manufacturer. This keeps the oil passages to the turbo clean and free from clogging.
• Use the right oil: Use an oil grade recommended by the manufacturer. The oil keeps the turbo bearings lubricated.
• Let the engine idle: Forcing the car to turn off the engine right after driving can damage the turbo. Always let the engine idle for a while before turning it off. This allows the turbo to cool down.
• Inspect the wastegate: The wastegate regulates how much exhaust goes into the turbine. A faulty wastegate will ruin the turbo. Always check if it is working properly.
• Check the intercooler: The intercooler cools down air that has gone through the turbine. A faulty intercooler will make the engine run hot. Always check if it is working properly.
• Check for oil leaks: Oil leaks can occur anywhere from the oil tank to the turbo. Always check for oil leaks.

How to choose universal engine turbochargers

Wholesalers should consider several factors when selecting the appropriate turbo for engines to meet their project's needs. They include:

• Engine Size and Specifications

  The universal turbocharger chosen should match the engine's size and specifications. Larger engines can get more airflow from bigger turbos, while smaller engines work better with smaller turbos. The key is ensuring the turbo works well with the specific engine for maximum performance gains and reliability.

• Type of Driving

  Universal engine turbochargers are designed for different types of driving. Some focus on low-end torque for quick take-offs in city driving. Others might provide a broader powerband or top-end horsepower for highway or track driving. Consider where the vehicle will be driven most when selecting a turbo.

• Budget

  There are universal turbos for any budget, from affordable options to high-performance aftermarket brands. A higher price tag often means a longer lifespan and more consistent power delivery from upgraded turbos. However, an inexpensive turbo may be sufficient depending on the project's goals.

• Warranty and Support

  Choose a turbocharger with a solid warranty and manufacturer support in case of issues. Some aftermarket brands offer many years of coverage if installed correctly. Wholesalers can also find OEM replacement turbos with limited warranties. The key is finding reliable support in case something goes wrong with the turbo.

• Future Modifications

  If there are plans to modify the engine further down the road, select a turbo that can handle those changes. For example, a slightly oversized turbo may be needed if planning to add more intake/exhaust airflow or fuel injection later. It's better to err on the side of caution and choose a turbo that leaves room for future upgrades.

How to DIY and Replace Universal Engine Turbocharger

Replacing a turbo can be a complex task, but with the right tools and basic mechanical knowledge, it can be done. Here's a step-by-step guide on how to replace a turbocharger:

Tools and Materials Needed:

• Socket set
• Wrench set
• Torque wrench
• New turbocharger
• New gaskets and seals
• Oil and coolant

Step-by-step guide:

• Disconnect the battery: Before starting any work on a vehicle, it's important to disconnect the battery to prevent any electrical issues.
• Drain fluids: Drain the oil and coolant from the engine to prevent any spills or leaks while replacing the turbo.
• Remove the exhaust: Use a socket or wrench to remove the exhaust pipes connected to the turbo. This will allow access to the turbo from underneath the vehicle.
• Remove the intake: Remove the intake pipes connected to the turbo using a socket or wrench. This will allow access to the turbo from above the vehicle.
• Disconnect the wastegate actuator: Use a socket or wrench to disconnect the wastegate actuator arm from the turbo. This will allow the wastegate to open and close freely during the replacement process.
• Remove the bolts holding the turbo to the engine: Use a socket or wrench to remove the bolts holding the turbo to the engine. There are usually 3-6 bolts holding the turbo to the engine, depending on the vehicle model.
• Remove the old turbo: Once the bolts are removed, the old turbo can be easily removed from the engine.
• Install the new turbo: Place the new turbo onto the engine and align it with the mounting bolts. Make sure to use new gaskets and seals to prevent any leaks.
• Reconnect the bolts holding the turbo to the engine: Use a socket or wrench to reconnect the bolts holding the turbo to the engine. Make sure to tighten them securely to prevent any loose parts.
• Reconnect the wastegate actuator: Use a socket or wrench to reconnect the wastegate actuator arm to the turbo.
• Reconnect the exhaust: Use a socket or wrench to reconnect the exhaust pipes to the turbo.
• Reconnect the intake: Use a socket or wrench to reconnect the intake pipes to the turbo.
• Refill oil and coolant: Refill the oil and coolant into the engine.
• Reconnect the battery: Reconnect the battery to the vehicle.

Start the engine and let it run for a few minutes to ensure everything is working properly. Check for any leaks or strange noises coming from the turbo.

Q&A

Q1: What is the difference between a turbocharger and a supercharger?

A1: While both aim to increase an engine's power output by forcing more air into the combustion chamber, a turbo uses exhaust gases to spin a turbine and compress more air. On the other hand, a supercharger is mechanically driven by the engine itself, which makes it less efficient but better for instant power.

Q2: Can any car be turbocharged?

A2: In principle, any internal combustion engine vehicle can be turbocharged. However, not all engines are designed to handle the increased stress and heat from a turbo. It's essential to ensure the engine's components are compatible with the turbo before installation.

Q3: How long do turbochargers last?

A3: Turbochargers can last between 100,000 to 200,000 miles with proper maintenance. Factors like driving habits, oil changes, and using quality fuel also affect the turbo's lifespan.

Q4: Does a turbocharger require maintenance?

A4: Yes, turbochargers need maintenance to ensure they last and perform well. This includes regular oil changes, using quality fuel, and checking the intercooler and intake for leaks.