Table of Contents - MAHLE Aftermarket

WEATHERLY INDEX 002
Catalog No. TC-10-14
Table of Contents
2014-2015
Supersedes TC-10-11
Technical service..................................................................................................... Page 2
How to use............................................................................................................... Page3
Turbocharger diagnostics...................................................................................... Page4
Turbocharger damage
Oil carbon in bearing case............................................................................. Page6
Oil carbon deposits in oil pipe ...................................................................... Page7
Excessive loss of oil caused by blocked oil return line................................... Page8
Contamination of the compressor................................................................. Page9
Contaminated compressor wheel.................................................................. Page10
Cracked turbine housing............................................................................... Page11
Stress marks on compressor wheel.............................................................. Page12
Turbine wheel damage.................................................................................. Page13
Turbocharger tips
Turbocharger nomenclature.......................................................................... Page14
Turbocharger installation checklist ................................................................ Page15
Turbocharger nameplate identification................................................................. Page16
Glossary.................................................................................................................... Page17
Applications
Allis Chalmers............................................................................................... Page18
Audi.............................................................................................................. Page18
Caterpillar ..................................................................................................... Page18
Cummins...................................................................................................... Page21
Detroit Diesel................................................................................................. Page25
Ford.............................................................................................................. Page26
GMC............................................................................................................. Page26
IHC............................................................................................................... Page27
Isuzu............................................................................................................. Page27
John Deere................................................................................................... Page27
Mack............................................................................................................. Page28
Mercedes-Benz............................................................................................. Page28
Navistar......................................................................................................... Page30
Perkins.......................................................................................................... Page32
Volkswagen (VW).......................................................................................... Page32
OE Interchanges...................................................................................................... Page35
MAHLE Interchanges.............................................................................................. Page42
Comparison Chart of Turbocharger Manufacturers............................................ Page51
© MAHLE 2014 | 1
Technical Service
For technical service call:
1-800-248-9606
Hours: 8:30 am - 6:00 pm EST
(Monday - Friday)
highways. The sale or installation on emission
Use Of Clevite® engine bearings & engine parts,
MAHLE Original® pistons and rings and Victor
Reinz® gaskets products in aircraft or other
specialty equipment may be a violation of Local,
State or Federal Regulatory Agency laws, rules
and regulations.
These
products
components not approved by the California
Air Resources Board, which alter or modify the
original design or performance of such vehicle’s
emission control system is prohibited. Some
of the parts listed and offered for sale in this
catalog may fall within the above restrictions.
are
intended
solely
for
automotive applications. Under absolutely NO
circumstances should these products ever be
used in non-automotive applications including,
without limitation, aircraft engines, medical
equipment, atomic energy devices or reactors.
“Federal, State and local laws restrict the
removal, rendering inoperative, or in some cases
the modification of factory installed emission
devices or systems. California restricts the use
of parts which could increase emissions in
vehicles designed for use on public streets or
2 | © MAHLE 2014
controlled vehicles of certain emission control
Such parts are intended only for use on off-road
vehicles competing in competitive events or on
other types of vehicles which are exempt from
the applicable emission control laws. Installation
of these parts on vehicles subject to emission
control laws may be prohibited.
MAHLE Aftermarket recommends that the
applicable emission control laws be reviewed
before considering the installation of add-on or
modified parts.”
Teflon and Viton are registered trademarks of DuPont
Corporation.
How to use
How to use this catalog
This catalog uses a multiple column format (down, then over).
Each block has the following pertinent information.
1 =Application
2 = Application Notes
3 = OE Interchange*
4 = Part Number
*For a full list of competitors interchanges, see page X.
1
4
3
3
2
Part no. ending with 000 (xxxTCxxxxx000) = factory new
Part no. ending with 100 (xxxTCxxxxx100) = remanufactured to OE standards
Please note: The MAHLE Aftermarket turbocharger program covers the majority of vehicle
and engine applications. To allow us to offer our customers the widest possible range of
products, it contains not only MAHLE Original® turbochargers, but also products from other
renowned manufacturers in OEM quality. These turbochargers have been listed under a
MAHLE part number in our catalog for means of simplification.
© MAHLE 2014 | 3
Turbo diagnostics
Turbocharger diagnostic matrix
Maintenance and care
Turbochargers are designed to last for the service life of the engine. Monitoring is r­estricted to a few periodic checks that
should be performed during every engine service. One condition for achieving longevity, however, is exact compliance with the
engine manufacturer’s servicing specifications – such as oil change intervals, oil-filter system maintenance, oil-pressure checks,
­cleaning of all filter systems, and regular, professional filter changes.
Blue Smoke
Dirty air filter system
•
•
•
Air-intake and pressure line distorted or leaking
•
•
Excessive flow resistance in exhaust system/ leakage upstream of turbine
•
•
Possible Causes
•
•
Oil leakage at turbine
Black smoke
Problem
probably recur with a new turbocharger.
�Please do not disassemble any part of the turbocharger.
Oil leakage at compressor
�If the true causes of damage or failure are not found and corrected, they will
High oil consumption
�Such causes must be eliminated before the turbocharger is replaced.
Turbocharger is noisy
�This matrix is intended to help pinpoint the causes of damage or failure.
Boost pressure too high
diagnostic table below to find your cause.
Low power/boost pressure too low
It is crucial to analyze an detect why the turbocharger has failed. Please use the
Compressor/turbine wheel defective
Power losses and faults – the causes are frequently not inside of the turbocharger
•
•
•
Oil feed and drain lines clogged, leaking or distorted
•
•
•
•
Crankcase ventilation clogged or distorted
•
•
•
•
Coke or sludge in turbocharger bearing housing
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Fuel system/injection system defective or improperly adjusted
•
Valve guide, piston rings, engine, or cylinder liners worn/increased blow-by
•
•
•
Dirty compressor or charge air cooler
•
•
•
Boost pressure control swing valve/poppet valve does not close
•
•
Boost pressure control swing valve/poppet valve does not open
•
•
•
•
•
•
Control line to swing valve/poppet valve defective
•
•
Piston ring seals defective
•
Turbocharger bearing damage
•
•
•
Foreign-body damage to compressor or turbine
•
•
•
•
•
•
•
Exhaust gas leakage between turbine outlet and exhaust pipe
•
•
•
Engine air collector cracked/missing, loose gaskets
Turbine housing/swing valve damaged
•
•
•
•
Insufficient oil supply to turbocharger
•
•
•
•
4 | © MAHLE 2014
How turbocharger damage is caused
Defects on the exhaust-gas turbocharger mostly
have one of the following causes:
nInadequate lubrication
If there is insufficient lubrication, the bearings
will fail and the compressor and turbine
wheels grind against their housings.
nContaminated oil
Contaminated oil leads to score marks on
shaft journals and bearings. Oil bore holes
and seals ­
become clogged and cause
insufficient oil supply.
nIntrusion of foreign bodies
Foreign bodies that, for example, enter
through a defective air filter, damage the
turbine or compressor wheels. The resulting
unbalance damages the turbocharger
bearing.
What must be followed when handling
­turbochargers
The turbocharger is a technically complex unit
with precisely matched components. When
handling, the turbocharger it is important to:
nTrain repair shop personnel
Turbochargers reach speeds of up to
300,000 rpm. Their individual components
are made to minimum manufacturing
tolerances. Maintenance and replacement
should therefore be c
­arried out by suitably
qualified personnel. What is important here is
also the use of special tools and machines,
for example for balancing.
nDo not modify the turbocharger
Turbocharger design is optimized for a
specific engine type at the manufacturing
plant. For this reason, no a
­djustments or
modifications should be made to them. For
­example, if the boost pressure increases, it
may cause the engine to overheat, resulting
in damage to the pistons, cylinder head, or
engine mounts.
nUse the correct engine oil
Important when changing the oil: Only use
engine oil recommended by the manufacturer.
Any deviation in viscosity may cause incorrect
lubrication and damage the t­urbocharger.
Advice that competent car repair shops can
give their customers
Here are a few tips for the customers of car
repair shops which can help keep turbochargers
­running at top performance.
nIf the turbocharger is producing any
unusual noises, oil leaks, or vibrations
Stop the engine immediately and have the
engine checked by a technician.
nThe turbocharger needs time to lubricate
After starting the engine, it takes about 30
seconds until the oil flows completely through
the oil circuit. Only then may you rev the
engine at high speed.
nDo not shut the engine off immediately
If the engine was running at high speeds, do
not shut it off immediately. The reason is that
the t­urbocharger will continue to run without
sufficient lubrication. An important tip for car
repair shop customers: Before shutting down
the e
­ngine, let it run at idle for about 20
seconds.
© MAHLE 2014 | 5
Turbocharger damage
Oil carbon in bearing case
EFFECTS
�Blue-smoke
�Loss of performance
�
Loss of oil via turbine and compressor
�
Contamination in the charge-air cooler
�
Clogged exhaust gas cleaning system
�
Blocked control mechanism with adjustable turbochargers
POSSIBLE CAUSES
nUse of unsuitable engine oil (poor quality)
nTurbocharger overheating
nImmediate switch off of the hot engine
CORRECTIVE/PREVENTATIVE ACTION
nPay attention to the prescribed oil grade.
nLet the hot engine run on for at least one minute.
nPay attention to the necessary measures during tuning.
nFlush the oil after turbocharger damage so that no deposits enter the lubricant circuit.
nDismantle oil pan and clean carefully.
nReplace the turbocharger after flushing with oil.
nPay attention to installation instructions.
nObserve oil change intervals.
nSignificantly shorten the oil change interval if running with bio-fuel.
nChange the oil and oil filter as well as the air filter when replacing the turbocharger.
6 | © MAHLE 2014
Oil carbon deposits in oil pipe
EFFECTS
nBlue-smoke
nLoss of performance
nTotal failure of the turbocharger
nHeavy contamination of the charge-air cooler with foreign bodies
nClogged exhaust gas cleaning system
nNoise from turbocharger
POSSIBLE CAUSES
nOverdue oil change interval
nUse of unsuitable engine oil (poor quality)
nIncorrectly installed oil pipe
nMissing heat shield
CORRECTIVE/PREVENTATIVE ACTION
nReplace oil feed pipe when replacing the turbocharger.
nUse manufacturer specified oil grade and follow oil change schedule.
nThe charge-air cooler must be replaced if the turbocharger is damaged.
nChange the diesel particulate filter and check the catalytic converter if the turbine wheel was
damaged.
nCarefully clean the intake system.
nChange the oil and the oil and air filter when replacing the turbocharger.
nSignificantly shorten the oil change interval if running with bio-fuel.
nPay attention to installation instructions.
© MAHLE 2014 | 7
Turbocharger damage
Excessive loss of oil caused by blocked
oil return line
EFFECTS
nBlue-smoke
nLoss of performance
nEngine oil is forced into the turbine and compressor
nSeized or stiff mechanical parts (adjustment, bypass, wastegate, …)
nHeavy contamination in the charge-air cooler
nEngine oil collects in the charge-air cooler
nClogged exhaust gas cleaning system
POSSIBLE CAUSES
nConstriction or bend in the oil return line
nExcessive oil level in engine
nUse of sealing compound instead of gasket set
nReplace the return line but without changing the engine connection
CORRECTIVE/PREVENTATIVE ACTION
nUse only the matching mounting gasket set.
nExchange oil lines.
nClean the oil return line connection to the engine.
nDismantle oil pan and clean carefully.
nCarefully clean the charge-air cooler, replacement is better.
nIf mechanical parts are stiff (VGT™, bypass, wastegate, …) replace the turbocharger.
nChange the oil and oil filter as well as the air filter when replacing the turbocharger.
nSignificantly shorten the oil change interval if running with bio-fuel.
8 | © MAHLE 2014
Contamination of the compressor
EFFECTS
nBlack smoke
nLoss of performance
nNoise (whistling)
nContamination in the charge-air cooler
POSSIBLE CAUSES
nContamination enters the compressor via the intake system
CORRECTIVE/PREVENTATIVE ACTION
nCarefully clean the complete intake system.
nReplace air filter.
nReplace charge-air cooler.
nReplace turbocharger.
nRead out error memory and check the mass air flow sensor. Reset service engine codes and
clean the mass air flow sensor.
nChange the oil and oil filter as well as the air filter when replacing the turbocharger.
© MAHLE 2014 | 9
Turbocharger damage
Contaminated compressor wheel
EFFECTS
nBlack smoke
nLoss of performance
nNoise (whistling)
nContamination and damage to the charge-air cooler
POSSIBLE CAUSES
nLoose deposits from the crankcase ventilation
nIce in the intake system caused by condensation
nFragments from from previously damaged turbocharger
nLeak in the intake system
nAbrasive wear of compressor blades
CORRECTIVE/PREVENTATIVE ACTION
nCarefully clean the complete intake system.
nCarefully clean or renew the crankcase ventilation.
nReplace turbocharger.
nReset service engine codes and clean the mass air flow sensor.
nChange the oil, oil filter and air filter when replacing the turbocharger.
nCarefully clean or renew the charge-air cooler.
nClean the air intake system.
nCheck intake system for leaks.
10 | © MAHLE 2014
Cracked turbine housing
EFFECTS
nLoss of performance at low speeds
POSSIBLE CAUSES
nOverheating through incorrect setting of the injection system
nInappropriate tuning
CORRECTIVE/PREVENTATIVE ACTION
nReplace turbocharger.
nChange the oil, oil filter and air filter when replacing the turbocharger.
nAllow engine to return to normal operating temperature.
nCheck the engine management system.
© MAHLE 2014 | 11
Turbocharger damage
Stress marks on compressor wheel
EFFECTS
nBlue-smoke
nLoss of performance
nNoise
nHeavy contamination in the charge-air cooler
nClogged exhaust gas cleaning system
POSSIBLE CAUSES
nBearing damage due to contaminated oil
nBearing damage due to lack of oil
nIncreased exhaust back pressure
nClogged air filter
CORRECTIVE/PREVENTATIVE ACTION
nCheck bearing clearance of the turbocharger shaft.
nCheck condition of engine oil, flush engine if necessary.
nCheck oil pressure.
nChange the oil and oil filter as well as the air filter when replacing the turbocharger.
12 | © MAHLE 2014
Turbine wheel damage
EFFECTS
nBlue-smoke
nLoss of performance
nNoises
nHeavy contamination in the charge-air cooler
nClogged exhaust gas cleaning system
nStiffness of mechanical parts (adjustment, by-pass, wastegate, ...)
nElectronic control unit switches to emergency programme
POSSIBLE CAUSES
nContamination enters the turbine via the engine
nLoose parts in the exhaust manifold and exhaust gas cleaning system
CORRECTIVE/PREVENTATIVE ACTION
nEndoscopic examination of combustion chambers.
nCheck exhaust gas cleaning system for contamination and mechanical damage.
nCheck and if necessary replace all turbocharger oil lines.
nCheck and if necessary replace charge-air cooler.
nCheck and if necessary replace compensator pipes and manifold.
nReplace turbocharger.
© MAHLE 2014 | 13
Turbocharger tips
Turbocharger nomenclature
Oil inlet
Vacuum unit
Rotor shaft
Turbine wheel
Compressor wheel
Compressor inlet
Turbine outlet
Compressor outlet
Oil return
Turbine inlet
14 | © MAHLE 2014
Turbocharger installation checklist
Before Installation
After Installation
nDiagnose and solve the reason for the failure
nldle for approx. 120 seconds after engine is
of the old turbocharger (possibly a fault on or
around engine)
running
nDuring idling: All connections (air, exhaust,
nCompare turbocharger model number with
water and oil) checked for firm seating,
the engine specifications and the turbocharger
tightness and free of leaks, gas-tightness
manufacturer’s model number
checked with soapy water if necessary
nCheck for proper engine cooling
nMonitor oil pressure
nCheck oil supply, make sure oil return from
nAfter 20 operating hours or 650 miles, check
the turbocharger to the crankcase is clear
nIntake, charge air and exhaust area:
- Check for functional capability
- Clean out any contamination by foreign
bodies or fluids and solve why they were
present
- Clean any undamaged air supply hoses
and pipes
nIn the case of liquid-cooled turbochargers:
check for adequate coolant flow
nCheck whether an adjustment of the housing
position is necessary
nTorque fasteners as specified by the engine
and vehicle manufacturer
all relevant connections again for firm seating,
tightness and free of leaks
Important note for car repair shops:
The turbocharger may only be installed by
skilled personnel. Incorrect installation, use and
operation of the turbocharger or modifications
to it can cause damage to the turbocharger and
the engine. The manufacturer’s specifications as
well as the installation and start-up instructions
must be followed. No liability for material
defects shall be accepted if a turbocharger is
installed that does not comply with the engine
specifications or if the installation and fitting
instructions have not been followed. Visible
faults must be reported immediately.
nMake sure the flanges and threads are free of
damage, debris and wear
nUse only brand new gaskets and seals
nChange engine oil and filter as specified by
the engine and vehicle manufacturer
During Installation
nBefore securing the oil supply line the
turbocharger should be filled with new engine
oil through the oil inlet hole, while slightly
turning the rotor manually
nAttention paid to correct handling
© MAHLE 2014 | 15
Turbocharger nameplate identification
How to look up a Turbocharger
MAHLE ORIGINAL
Manufacturer part number
Manufacturing code
GARRETT
OE part number
Manufacturer part number
Serial number
Model
HOLSET
Manufacturer part number
Serial number
OE part number
Model
KKK (K TURBO SYSTEMS/BORG WARNER)
OE part number
Model
Serial number
Manufacturer part number
SCHWITZER (BORG WARNER)
Manufacturer part number
Serial number
16 | © MAHLE 2014
Glossary
Definition of Terms
Bar – A unit of pressure. 1 Bar = 14.5038 P.S.I., 2500 Bar = 36,259 P.S.I.
Compound Turbo System – A compound turbo system utilizes two different sized turbochargers,
each mitigating the weaknesses of the other. The small turbo allows it to spool up faster, making
it more responsive to improve drivability. The 2nd turbo has exhaust gases directed to it on an as
needed basis to either enhance or replace the boost generated from the first turbo. The combination
of the two can offer a low to zero turbo lag.
Hot Shut Down – An issue associated with failures of turbochargers happening when the vehicle is
shut down during above the average operating temperature range. This typically only occurs when
racing or pulling a load. The wheels spin from 100-250,000 rpm. As the engine turns off so does
the supply of pressurized oil for lubrication. Because these units can run in excess of 1800 degrees,
the oil becomes cooked (coking) and sticks to the outside wall of the oil supply line, hampering the
supply of fresh oil available when the engine starts the next time.
Mounting Pedestal – The Ford 7.3L Power Stroke® engine is the only application for it. This
mounting bracket incorporates an engine oil operated EGB.
Turbo Lag – The time required to change speed and function effectively in response to a throttle
change. Lag may be noticeable under any driving condition and becomes a significant issue under
acceleration. This is indicative of the time needed for the exhaust system working in concert with
the turbine to generate enough extra power to accelerate rapidly. A combination of inertia, friction
and compressor load are the primary contributors.
Turbocharger – A device used to compress the intake air that is used to enhance the air fuel
mixture to provide either more power or better efficiency. A turbocharger is powered by a turbine
which is driven by an engine’s exhaust gases. The turbine is mounted on a common shaft and has
a compressor wheel mounted on the other side.
Twin Turbocharger – Two of the same turbochargers mounted on the same engine doing the
same job – both compress the intake charge. Each turbocharger is driven by half of the engine’s
exhaust gases. The advantage is less turbo lag than a single larger turbo.
VGT™ (Variable Geometry Turbocharger) – Usually designed to allow the effective aspect ratio
of the turbo to be altered as conditions change. By altering the angles of the vanes in the turbine
housing, as the engine accelerates, the turbo’s aspect ratio can be maintained at its optimum. The
benefit is having a minimal amount of lag, a low boost threshold, and efficiency at higher engine
speeds
VNT™ (Variable Nozzle Technology) – Similar in design as VGT – movable vanes direct the
airflow of the exhaust gasses to hit the exhaust turbine at the optimum point for the most efficient
operation at varying speeds and loads.
© MAHLE 2014 | 17
ALLIS CHALMERS / AUDI
18 | © MAHLE 2014
CATERPILLAR
© MAHLE 2014 | 19
CATERPILLAR
20 | © MAHLE 2014
CATERPILLAR
© MAHLE 2014 | 21
CUMMINS
22 | © MAHLE 2014
CUMMINS
© MAHLE 2014 | 23
CUMMINS
24 | © MAHLE 2014
CUMMINS / DETROIT DIESEL
© MAHLE 2014 | 25
FORD
26 | © MAHLE 2014
GMC / IHC / ISUZU
© MAHLE 2014 | 27
JOHN DEERE / MACK
28 | © MAHLE 2014
MERCEDES-BENZ
© MAHLE 2014 | 29
NAVISTAR
30 | © MAHLE 2014
NAVISTAR
© MAHLE 2014 | 31
NAVISTAR / PERKINS
32 | © MAHLE 2014
VOLKSWAGEN (VW)
© MAHLE 2014 | 33
VOLKSWAGEN (VW)
34 | © MAHLE 2014
OE INTERCHANGES
© MAHLE 2014 | 35
OE INTERCHANGES
36 | © MAHLE 2014
OE INTERCHANGES
© MAHLE 2014 | 37
OE INTERCHANGES
38 | © MAHLE 2014
OE INTERCHANGES
© MAHLE 2014 | 39
OE INTERCHANGES
40 | © MAHLE 2014
OE INTERCHANGES
© MAHLE 2014 | 41
MAHLE INTERCHANGES
42 | © MAHLE 2014
MAHLE INTERCHANGES
© MAHLE 2014 | 43
MAHLE INTERCHANGES
44 | © MAHLE 2014
MAHLE INTERCHANGES
© MAHLE 2014 | 45
MAHLE INTERCHANGES
46 | © MAHLE 2014
MAHLE INTERCHANGES
© MAHLE 2014 | 47
MAHLE INTERCHANGES
48 | © MAHLE 2014
MAHLE INTERCHANGES
© MAHLE 2014 | 49
MAHLE INTERCHANGES
50 | © MAHLE 2014
COMPARISON CHART OF TURBO MANUFACTURERS
© MAHLE 2014 | 51
COMPARISON CHART OF TURBO MANUFACTURERS
52 | © MAHLE 2014
COMPARISON CHART OF TURBO MANUFACTURERS
© MAHLE 2014 | 53
NOTES
54 | © MAHLE 2014
NOTES
NOTES
NOTES
© MAHLE 2014 | 55
NOTES
56 | © MAHLE 2014
NOTES