Testing Your Turbo System

Many problems with turbo systems can be identified before the catastrophic happens through simple system testing.

Pressurize system to test for leaks

• Clamps — Check tightness
• Couplers — Check for holes or tears
• CAC core / end tanks — Check for voids in welds

Monitoring

The turbo system in your car should be monitored to insure that every aspect is functioning properly to give you trouble-free performance.

Instrumentation used to monitor / optimize system: The most accurate way to calibrate and optimize a system is through data logging!

1. Oil Pressure (Required to monitor engine operation)
   2. Oil Temperature (Required to monitor engine operation)
   3. Water Temperature (Required to monitor engine operation)
   4. A/F Ratio (such as a wideband sensor; required to monitor engine operation)
   5. Manifold Pressure
   6. Turbine Inlet Pressure
   7. Exhaust Gas Temperature
   8. Turbo Speed Sensor

Manifold Pressure

— Calibrate actuator setting to achieve manifold pressure required to meet hp target
— Detect over-boost condition
— Detect damaged actuator diaphragm

Back Pressure

— Monitor pressure changes in turbine housing inlet
— Affect of different turbine housing A/R’s
— Increased back pressure decreases Volumetric Efficiency thus decreasing ultimate power

Pyrometer

— Monitor exhaust gas temperature (EGT) in manifold / turbine housing
— Adjust calibration based on temperature rating of turbine housing material or other exhaust components Turbo Speed
— Determine operating points on compressor map
— Determine if the current turbo is correct for the application and target hp
— Avoid turbo over-speed condition, which could damage turbo

11 Point Checklist

1. Application Information – target horsepower, intended use of vehicle, etc.
   2. Air filter sizing — determine size for application needs
   3. Oil Supply — restrictor for ball-bearing turbo
   4. Oil Drain – proper size and routing
   5. Water Lines — set up for greatest thermal siphon effect
   6. Charge Tubing – determine diameter for application needs
   7. Charge-Air-Cooler — determine core size for application needs, design manifolds for optimal flow, mount for durability
   8. BOV – VTA for MAP engines and by-pass for MAF engines
   9. Wastegate – connect signal line to compressor outlet, smooth transition to external wastegate
   10. System Testing – pressurize system to check for leakage, periodically check clamp tightness and the condition of
   couplers
   11. System Monitoring – proper gauges/sensors to monitor engine for optimal performance and component durability