~ - ---i by Hugh Maclnnes TIIBLE 1I1111111TEIITI Introduction ....... 4 . .. 6Supercharging & Turbocharging .. Turbocharger Design.......... 12 , ChOOS'lngtheEngine.......... .. 27 Chaos n9the Turbocharger ........ 32 Carburet ion &FuelInjection ...... 49 19niticr...... 64 Exhaust Systems......... 67 Lubricati on....... . ........ 74 .......... 78 Intercooling .... 91 MarineEngines...... 97 Two-StrokeEngines ............ lOO HighAltitude Turbocharging.110 Installations Do's Don'ts &Maybe's .119 Tractor Pulling ..128 Maintenance............. ..132 Kits&fWheretoBuyThem ExhautEmisSions... Waternlectlon . .136 .152 .157 ...... 160Motorcycles .. Turbocharging theIndyEngine.. 163 Appenrix.............. 168 GIOfsary.............168 2 Symbols ...169 Y -rabies.... 170 Alti;tude Chart.... .172 TurbochargerFail ureAnalysis ... 173 Acknowledgements.... .. 174 Compressor SelectionChart...175 HorrepowerIncreaseChart.. Manufacturers &Distributors. , KitMakers&Instaliers ... Editor &publisher: IBillFisher COl/erdesign; I JoshYoung BtOk design&assembly: NancyFisher Text &caption typography; LouDuerr,MarciaRedding Figures: .175 .188 . 192 WilliamPine,ErwinAcuntius Cdl/erphoto; IPhotomation Photography: HughMaclnnes.BillFisher. HowardFisher, others -"HurryRoundHondo" jet boatisGaleBanksEngineering's racingtest bed.Enginein hullissameasthe one on the cOl/er of thisbook.Boat holds A.P.B.A."K" Class(un limited)JetBoat1600 meter courserecord:1 12.5MPHfor5miles.Boat alsowon 1975 Jet BoatNationals. Stockbore &stroke 454 CIDChel/roletbigblockproduced 1,067 Ibs.ft.torque at 8,300RPM;1,687HPat 281bs.boost withstraight alcohol. Engineequipmentincludes Carillorods,forgedpistons with1.094inchChrysler Nascarpins,IskenderianroUer camshaft androcker arms,Oringedblock and heads, polished combustion chambers, stockports, 7116-inchpush rods. TE0-691turbo chargers and the23/8 inchwasteyate areAiResearchunits.Banks'shop didthe blue-printing and assemblyandsupplied the stainlesssteelexhaust system featuringOrings on cast stainlessheader flangesand expansionbellows to prel/ent stress cracking.No intercooler wasusedinthis configuration.Boat photo bVA.Bond. ISBN:0-91265649-2 LibraryofCongress Catalog CardNo.766002 H.P.BookNo. 49 1976PrintedinU.S.A.676 H.P.Books,P.O.Box5367 Tucson,AZ85703 602/8882150 Anindependent pUblication-nO! asso ciated withAIResearchIndustrialDivi-sion ofGarrett Corporation,Rajay Industries.Inc., Schwitzer Corporation. Roto.Master, or anyotherrurbocharger manufacturer orinstaller. or kitbuilder. NOTICE:The information con tamedin thisbookIStrue and complete to thebest of our knowledge.Allof therecommenda tions onturbocharger sizing. matching,in stallationandusearemadewithout any guarantees onthepart oftheauthors or H. PBooks_Because designmatters, engineering changes and methods of appli cationarebeyond our control.the author and publisher disclaimanyliabilityin-curredinconnectionwiththe useofthis dara or specific derails. AlIi$On1720 CIDengineturbocharged by Skip Cooley might endup inanunlimited hydroplane- or inatractor-pulling contest.Either 0HPon methanolfuel.Ai ResearchT18A turbos, Schwitzer waste gates and Aviaidscavengepumps arepart of the pack-age.il theold gear-drivensupe rcharger gains200 HP.Bellows connector to turbine stillneedsto be connectedhere. USACFordRaceEngine159.5 CIDpro-duces 700900 HP.It wonallUSAC500-mileracesfrom1969-71.Nowbuilt as theFoyt engine,thisistypical of the' V8powerplants usedinsomeUSAC Championship Cars. Photo by McGuir. Studio. 3 , introductiontomybook, Select alld InstallTurbochargers, itslllrtedoutasaJO-pagc butkept growing.Bythetime ithadgrownto aJ 44-. After threeyears,itwas due Thisbookstartedoutas r.It soonbecameapparent 1 newitems werebeingadded itfarmorethanasimplercvi-,I decidedto star! '>1&1ClI901060ItlOLSO11>01t1O Z66SlGG96ll'69lG606(GSllB09B l>I>aLlS118I>6t8ll19t'>PlUlIII 61919991>"96Z91996'>6L'>959t:r9L'>SS'>ZI>"l'>1S II101POO99061>0lCOSIO .,._-_.,._-,--

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'".867 9 ,,, '" '" '" "" ", '",n '" ,,, '" EXAMPLE' Pn/ PT1 1' = 1.82 Airflow "290 CFM Tll IOlettempeo-ature " 192+ 460)oR "5520R { f romfIgure51=68% y(from!8blel..0.18468 T I(idealtemperatUfe rise) t::.TAtactualtemperalUrerlsel T, xY=552x18468= 102 .o. T,",ill ..l SOo n.c.68 T 2{compres$OroullellempernlUrel= Tit A T A92+150 '"242 F RichardTwiUey of Albuquerque,NewMexico, turbo-ed this 292 CIDChevyand"eldhi s ownagainstV-S's on theregionalsprint -car circuit.AiResearchT12 turbo oncepressured a Cate rpiUer buUdozer. failure analysis by Elmendorf, ServiceEngineer, Schwitzer DesPit1theoutwardappearanCIlofuuer simplicity,themoder nDiesel ,S, infact,theendproductofahighlyspeCialized andthoughnOtreadilyapparent onfirstOIfenJ8tion, the methods usedinturbo-chargermnnulaclurehavebeenbroughttoa highlellel lolsophisticat ion,particularlyduring the pasttJo decades. Thedemandsonthistechnology aremade the DreaSof metallur gy.dimenSion-altoleranecontrol,anddynamicunbalantt correction,ThereasonsloremphasIs intheseareasareeasytoappreciate,oncethe typicalslteswsactingonaturbochargerare known.Innormaloperation,then,gasintro-., ductlont1mperaturescanells!lyexceed1.000 F,rotat iv!speedscanrunabove70.000RPM. andthe'lternalpoweroftheturbocharger can apwoachvaluesequivalnnltoIhnlIywhnel horsepow,r ofthe engine. Itisknowneventomostnnophytesthat turbocharrrfailuresareinherentlyandhaveI devastat ' ''geffectone"gineper for. mance.11ISaWIdespreadmisconceptioneven amo"gtheseasoned"experts",however,that all lailuresoccurinsIJ"taneously ofprimar,lyinternalcauses.andaretherefore u"prevenl!1ble;ontheco"trary.the vastmajor ityof arethedirectresultoffaulty enginemaintenanceor operation. and mallYare .,. progresslvfon"ature. Itist1epurposeofthisbulletinto acquaint theowneroroperatorofa"turbO"-equipped enginewi t htheseveralcategoriesofcommon failure.tqhelphimrecognizethesymptoms witheach,arIdhopefully.10enable himtoaI' oidtheexpenseandaggrav!ltionof repetitivefailures.However,10developa complete and well -roundedturbocharger service program,itissuggestedthattheinformation contained!hereinbesupplementedwiththe we!llthofroutinearIdpreventivemamtenance inlormatinavailableforboththecomplete engineaidtheturbochargerassemblyalone. FAILURESRELATED TOFAULTY vitalroleinthelifeofa turbo charger,lfcauseitservesthetriplefunctionof coolingandcleansingmanyofthe mostcriticalandhighlystressedpartsinthe assembly. Evenfomentaryinterruptions inthesupply 01high9ua litylubricationcanproducedisas-trousresults,butparticularlyundercondItions ofhighsred or heavyload, Thereareseveralfacetstoproperturbo-chargerlubricatlo",andasaconsequence," def,CIencyofanyoneaspectusuallyproduces aspeCIf IC symptom. AbrasiveContamination- Thepresence ofsuffi -cient materialillthelUbricatingoil WIllresultInwearofthevariousbearingsur face5,andISusuallymostprevalentonthe thrustbearingandoutsidediametllrsofthe sh"ftbearings.Occasionally,theabras,ve particlesaresosmal lthattheyescapethe centrifugeeffectoftherapid lywinningbear-mgs;insuchacase,considerablescouringof theJournalsectIonsoftherotor shaft mIght 00 noted. The depth of scratching and amount of wear callvarywidely.anddependprimarilyonthe degreeandn"tureofthecontaminant,the operatlllgtimeaccumul3ledwiththecontami -nantpresent.andthesilverityofenginu operation. InsufficientPressureorFlow-Itisessential thatasufficientquantity01oilflowthrough theturbochargeratalllimestoensuresuspen-sionandstabilizationofthefullfloating! rotati"gbearingsyHem,andtocontinually washheatfromtheunit,therebykeeping internaltemperatureswlthlllworkablelimits. Themostfrequentlyseend"ma!JCthatcan berelatedtoinsufficientoilflowistheresult ofwhatmightbetermedthe"oillagsyn drome."Thisinvolvesafaultyoperati"9habit, inwhichacoldIUrbochargedengineisstarted andimmediatelytakentoaconditionofhigh speedOfheavyload.Insuch acaw,therotative speedoftheturbochargerapproachesthepcak allowablevaluebeforeaneffectIve001cush,oll is tosustainthe bearings. The result isrotorgyral ion(oftencalled"shaftmotion" or"whirl")withattendantdistressofthe bea rings. Marginaloilflow-thatinwhichsufficient oilIScirculatingtopreventasudelenfaljure-callalsoproducedetrimentaleffects,themost notableofwhichISIhegradualaccumulation ofvarnishoninternalsurfaces.whichmakes unitd isassemblyqui tedifficult. ImproperOilTypeorLackofChangeat RecommendedI ntervals_Theprincipalcondi tionnoted when either ofthese conditions exist isgeneralizedsludgeorvarnishformationon theInternalsurfacesoftheturbocharger;these areusuallyfoundtobeheaviestattheturbine endoftheunit.becausethehigherprevailing temperatureinthatarearesu lt sinaccelerated lossofvolatile oilcomponents. Incertainapplications,thisvar nishforma t ionc!luseseventualsealringfoulingandwear, andca"onlybecorrectedbycomplet eunit teardownandreplacementofthetu rbine wheeJand-shaftassembly;thisisaveryexpen sivepropmition, atbeSt. FAILURESRELATED TOFOREIGN MATERIALINTAKE ThevulnerabIli t yofaturbochargerwil l becomeinstantlyapparentthetirsttimea pan,cleofsignifica"tSIze1$ inductedinto eitherthecompressororturbInesectionwi t h the unit at spC--Z w u a: w Q. 2 00 80 GO 40 2C 00 8C 6 4( 2( ( 2 11 0 9 8 7 6 5 4 3 2 I . , ~ , , - -_... \}" / VMAX. / VMIN. // / / // // 1// 1// ;,[/ V o4812162024283236 BOOST(PSI) \\ \ 1\S \\ 1\ \ 1\\ \ \ 1\ \ h;'" E I ~ \\ \ E "" ~ '-... t'-... B K I ~~ "-... '-.... \ '-... ~ "-"-I'----I'-----"" ~ "---. "-r-..... ---'-. '" "----lOO200300400500 CUBICINCHDISPlACEMENT ~ 40 r--. "-Rajayprovidedthis chart showing typical horsepower increases forwrbocharged passenger-car enginesatvariouslevels of boost. OougFraserRacingEngines uses this chart forquickly calculating whichturbocharger compressor sizeto usewithvarious engine sizesandRPMlevels. 1 1 j I I . , 175-.i OILINU7II Z:W - 18NPT(AS5.#0"",01) OILINLETiIT/'[.9,';;';J.38PM OILINLET -+ I [7':-;,'",....,"... , " ".'r""" "'''" .' K'0""'0''''L.\tI,.,. wrLri D---, , --5:352---l-3LD-3050NLY o ol'.'" isN .-"::i:I .- . 1, '/", I 1I, -t't ", -jI : + ' L J.-,', .. _- It", COUPLING DrMS. __----.. 2.882 .03R. TURBOCHARGERSUB-ASS'Y, OUTLINE SCHWITZERMODEL 3LD(TYPICAL) ROUND, STRAIGHT" SMOOTH fORTHIS DISTANCE----...... T tA8 -- HALLANOALE,FLORIDA, U.S.A. AIR OUTLET(TYPICALI

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