cherniy_chack wrote:Hay,Wotisname .
The fact that after the repair your engine makes a lot of noise and smoke suggests that the turbocharger after the repair does not develop the intended boost pressure.
Without load, the boost pressure can be about 0.2 ... 0.3 atmospheres, moving in fifth gear on a flat road at a speed of about 100 km / h-0.4 ... 0.5 atmospheres, when driving uphill and abruptly acceleration cannot be less than 0.6 ... 0.7 atmosphere.
In 2015, I installed a turbocharger on my engine and connected a pressure gauge to measure the boost pressure.
The most common cause of low boost pressure after a turbocharger repair is incorrect adjustment of the length of the drive rod from the pneumatic drive to the gate.
Or air leakage due to a leak in the boost duct.
Interesting you should meantion this at this time as I was discussing this yesterday at my local garage. But firstly I must correct your first sentence. My engine hums like a Swiss watch and is totally smokeless. The only unexpected noise is the hammer/anvil noise from the injection pump. The amount of power that I am getting is less than I got with the old 2.5di engine ie. down to third gear and 25 mph to get up the hill in the old Mersey Tunnel. Before yesterday's adjustments I'd have been in second gear and 20 mph. The old engine would have been in 4th and on the speed limit of 30 mph, incidently the rebuilt engine is much quieter. So clearly there is more to do before I adjust the waste-gate of the turbo but I have ordered a boost gauge as a next step. I have already blanked off the EGR and blanked off the small vacumm pipes as I don't have any of the electronics to run it.
Having been inside both engines I can report there is not much difference between a non-turbo and a turbo engine. The swish bowel in the piston top is slightly larger in the turbo engine and there is a recess machined in the head between the exhaust and inlet valves about 4mm deep and about the size of the inlet valve head. This is because the turbo engine has a little less compression. These differences are so small that I believe a turbo could probably be bolted onto a 2.5di engine without any other changes except the injection pump. The head on my turbo engine started life as a non-turbo 2.5di and I machined the recesses, and fitted turbo pistons and turbo injectors. There is no difference between a 2.5di and a 2.5tdi block. All the drillings are there for the oil feed to the turbocharger. The sump in the non-turbo needs a drain pipe fitting. Incidently 4 heads were rejected for the rebuilt engine before I found one without cracks between the exhaust and inlet seats of no4 cylinder.
The local injection pump expert claims the advance and retard on Bosch pumps often stick, can this be checked without removing the pump. It is not that I don't want to spend the £120 to have it checked just I don't have any other wheels at this time.