Worksheet Turbo
-
Upload
abdul-al-hadi -
Category
Documents
-
view
99 -
download
2
Transcript of Worksheet Turbo
INTAKE AND EXHAUST – Specifications
GENERAL SPECIFICATION (4D56)
Items Specifications
Air Filter
Type Dry Type
Element Unwoven Cloth Type
Exhaust System
Front Exhaust Pipe 4D56 Single Type
Muffler Expansion Resonance Type
Coupling Spherical Coupling and Flat Coupling
Turbocharger
Type Exhaust Gas Turbine Type
Identification Number TD04-11G-4
Supercharging Pressure Control Waste Gate Actuator
Intercooler
Type Air Cooled Type
SERVICE SPECIFICATIONS
Items Standard Limit
Intake And Exhaust Manifold
Distortion of Cylinder Head Contacting
Surface mm (in)
Less Than 0.15
(0.0059)
0.3 (0.012)
Turbocharger
Initial Starting pressure of waste gate
actuator kPa (kg/cm². psi)
91 (0.91, 13) -
1
INTAKE AND EXHAUST – Specifications
INTAKE AND EXHAUST MANIFOLDS
Remove And Installation
Removal Steps
1. Intake Fitting 7. Stay 13. Gasket 19. Gasket
2. Intake Fitting Gasket 8. Heat Protector “B” 14. Oil Pipe 20. Intake manifold
3. Air Hose 9. Heat Protector “C” 15. Oil Hose 21. Engine Hanger
4. Boost Hose 10. Exhaust Fitting 16. Oil Return Pipe 22. Exhaust manifold
5. Waste Gate Actuator 11. Exhaust Fitting Gasket 17. Gasket 23. Exhaust Manifold
Gasket6. Heat Protector “B” 12. Eyebolt 18. Turbocharger Assembly
2
ENGINE – Turbocharger
DISASSEMBLY AND REASSEMBLY
Disassembly Step
1. Hose Clip
2. Hose
3. Coupling
4. Turbine Housing
5. Snap Ring
6. Turbine Wheel Assembly
7. Compressor Cover
8. O.Ring
3
ENGINE – Turbocharger
SERVICE POINT OF DISASSEMBLY
REMOVAL OF TURBINE HOUSING
(1) Before disassembly, put mating
marks on adequate locations of the
turbine housing, compressor cover and
turbine wheel assembly, noting their
relative position so as to ensure correct
reassembly.
Caution
When disassembling, use care
not to cause damage to the
compressor wheel and turbine
wheel blades.
REMOVAL OF SNAP RING
(1) Lay the unit with the compressor
covers side facing down and using
snap ring pliers. Remove the
compressor cover attaching snap ring.
Caution
When removing the snap ring,
hold it with fingers to prevent it
from springing away.
4
ENGINE – Turbocharger
SERVICE POINT OF DISASSEMBLY
REMOVAL OF TURBINE WHEEL
ASSEMBLY
(1) Remove the turbine wheel
assembly, striking the circumference of
the compressor cover with a plastic
hammer.
The turbine wheel assembly may be a
little hard to remove due to an a-ring
put on the outer circumference.
CLEANING
(1) Use clean cleaning oil commercially available. Do not use corrosive cleaning
oils as they could cause damage to some parts.
(2) Use a plastic scraper or hard brush to clean aluminum parts.
INSPECTION TURBINE HOUSING
(1) Check the housing for traces of
contact with the turbine wheel cracks
due to overheating, pitching,
deformation and other damage.
Replace with a new turbine housing if
cracked.
(2) Operate the waste gate valve lever
manually to check that the gate can be
opened and closed smoothly.
5
ENGINE – Turbocharger
SERVICE POINT OF DISASSEMBLY
NOTE: COMPRESSOR COVER
(1) Check the compressor cover for traces of contact with the compressor wheel
and other damage.
TURBINE WHEEL ASSEMBLY
(1) Check the turbine and compressor
wheel blades for bend. Burr damage
corrosion and traces of contact on the
backside and replace if defective.
(2) Check the oil passage of the turbine
wheel assembly for deposit and
clogging.
(3) Check the turbine wheel and compressor wheel for light and smooth turning.
OIL PIPE Oil RETURN PIPE
(1) Correct or replace the oil pipe and oil return pipe if clogged, collapsed,
deformed or otherwise damaged.
SERVICE POINTS OF REASSEMBLY
INSTALLATION OF O-RING
(1) Apply a light coat of engine oil to a
new a-ring and fit in the turbine wheel
assembly groove.
Caution: When installing the O.Ring,
use care not to damage it. A damaged
O-ring causes oil leaks.
6
ENGINE – Turbocharger
SERVICE POINT OF DISASSEMBLY
INSTALLATION OF TURBINE WHEEL
ASSEMBLY
(1) Assemble the turbine wheel
assembly and the compressor cover
together. lining up the mating marks put
at the time of disassembly.
Caution: Use care not to damage the
blades of turbine wheel and
compressor wheel.
INSTALLATION OF SNAP RING
(1) Lay the assembly with the
compressor cover facing down and fit
the snap ring.
Caution
Fit the snap ring with its chamfered side
facing up.
INSTALLATION OF TURBINE
HOUSING
(1) Install the compressor cover and
turbine wheel assembly to the turbine
housing. Lining up the mating marks
put at the time of disassembly.
Caution : .Use care not to damage the
blades of turbine wheel.
7
ENGINE – Turbocharger
SERVICE POINT OF DISASSEMBLY
INSTALLATION OF COUPLING
(1) Install the coupling and tighten to
specified torque.
INSPECTION OF WASTE GATE
ACTUATOR OPERATION
(1) Check that the rod moves when the
following pressure is applied using a
tester. Check as installed on the
engine.
8
ENGINE – Turbocharger
SERVICE ADJUSTMENT PROCEDURE
TURBOCHARGER SUPERCHARGING PRESSURE
INSPECTION <4D56>
Caution: Two people at a place where
fully open acceleration can be done
should carry out the driving test, and
the person in the passenger seat
should make reading of the
measurement values on the pressure
gauge.
(1) Remove the hose that is connected to the fuel injection pump boost
compensator and install the pressure gauge via the T -joint, as shown in the
illustration.
(2) Accelerate the vehicle in second gear with the throttle fully open, and take a
reading of the measurement value on the pressure gauge when the engine speed
reaches approximately 3,000 r/min.
(3) If the pressure is not positive pressure, the reason is probably one of the
following, so carry out the following inspection.
Waste gate actuator is defective
Leaking turbo pressure
Turbocharger is defective
(4) If the turbo pressure is 83 kPa (0.83 kg/cm2, 12 psi.), the reason is probably
an abnormality in the turbo pressure control, so carry out the following inspection.
Waste gate actuator rubber hose is disconnected or burst
Waste gate actuator is defective
Waste gate valve is defective
9
ENGINE – Turbocharger
SERVICE ADJUSTMENT PROCEDURE
WASTE GATE ACTUATOR INSPECTION <4D56>
INSPECTION <4D56>
(1) Connect a hand pump
(pressurization type) to the nipple.
(2) While gradually increasing the
pressure, check the pres-
sure where the waste gate actuator rod
begins to move [approx. 1 mm (0.04 in.)
stroke)
Standard value: 91 kPa( 0.91 kg/cm2, 13 psi.)
Caution
To prevent damage to the diaphragm, do not apply pressure more than 104 kPa
(1.04 kg/cm2, 15 psi.)
(3) If the value is widely outside the standard value. Inspect the actuator or the
waste gate valve, and replace if necessary.
10
ENGINE – Turbocharger
REMOVAL AND INSTALLATION
Removal Steps
1. Air Temperature switch
connector
2. Intercooler fan motor
connector
3. Air hose B connection
(Intake Side)
4. Air Hose A-1 Connection
(Turbocharger Side)
5. Intercooler and Bracket
assembly
6. Air Hose A-1
7. Blanch Hose
8. Blanch Pipe
Joint
9. Blanch Pipe
10. Blanch Pipe
Bracket
11. Intercooler cover
12. Air Hose A-2
13. Air Hose B
14. Air Temperature
Switch
15. Bracket
16. Fan Motor
17. Intercooler
11
ENGINE – Intercooler
INSPECTION
Check the intercooler fins for bending damage or foreign matter.
Check the intercooler hoses for cracking. Damage or wear.
CHECKING AIR TEMPERATURE
SWITCH
(1) Immerse the air temperature switch
in the hot water shown in the figure.
(2) When changing the water
temperature. check for continuity
between the terminals with the circuit
tester.
12
INTAKE AND EXHAUST – Specifications
GENERAL SPECIFICATION (4M40)
Items Specifications
Air Filter
Type Dry Type
Element Unwoven Cloth Type
Exhaust System
Front Exhaust Pipe 4D56 Single Type
Muffler Expansion Resonance Type
Coupling Spherical Coupling and Flat Coupling
Turbocharger
Type Exhaust Gas Turbine Type
Supercharging Pressure Control Waste Gate Actuator
Intercooler
Type Air Cooled Type
SERVICE SPECIFICATIONS
Items Standard Limit
Turbocharger
Actuator Operating Pressure
When Operated 1mm (0.04 in)
91 (0.91) -
Cartridge Assembly Axial Play Of Shaft 0.057 – 0.103 -
Turbine Wheel Back to Turbine Back
Plate Clearance
0.39 – 0.83 -
13
INTAKE AND EXHAUST – Specifications
INTAKE AND EXHAUST MANIFOLDS
Remove And Installation
1. Eyebolt 7. Coupler 13. Gasket
2. Oil feed Pipe 8. Gasket 14. Turbocharger Assembly
3. Oil Return Pipe 9. Nut * Exhaust Manifold
4. Nut 10. Bolt * Turbocharger water outlet pipe
5. Coupler Insulator 11. Insulator B * Turbocharger water inlet pipe
6. Insulator 12. Insulator A
14
ENGINE – Turbocharger
INSTALLATION SERVICE POINT
TURBOCHARGER ASSEMBLY
Installation
(1) Prior to installing the turbocharger
assembly 14, pour engine oil into it
through the oil inlet hole A to lubricate
its component parts for smooth
movement.
(2) Using a tester, apply pressure to the
actuator B and read the pressure at
which the rod C begins to move
[approximately 1 mm (0.04 in,)]
If the reading deviates from the
specified standard value, replace the
actuator.
Caution: .Do not load the actuator B
with any more pressure than 117 kPa
(1.17 kg/cm2, 16.6 psi) nor carry the
turbocharger by holding the rod C, or
the diaphragm may be damaged.
15
ENGINE – Turbocharger
DISASSEMBLY AND REASSEMBLY
Disassembly Steps
1. Hose
2. Actuator
3. Coupling
4. Turbine Housing
5. Snap Ring
6. Compressor Cover
7. O-Ring
8. Cartridge Assembly
*1 Turbine Wheel
*2 Compressor Wheel
DISASSEMBLY SERVICE POINTS
TURBINE HOUSING REMOVAL
Caution: Tap allover the
circumferential surface of the turbine
housing 4 with a rubber hammers or
any other similar tool, using cares not to
damage it. The turbine wheel blades
are easy to bend. Use care so that they
do not contact the turbine housing 4.
16
ENGINE – Turbocharger
DISASSEMBLY AND REASSEMBLY
COMPRESSOR COVER REMOVAL
Caution: Tap allover the
circumferential surface of the
compressor cover 6 with a rubber
hammers or any other similar tool,
using cares not to damage it. .The
compressor wheel blades are easy to
bend. Use care so that they do not
contact the compressor cover 6.
CLEANING
TURBINE HOUSING/COMPRESSOR
COVER
(1) Prior to cleaning, visually check the
disassembled parts for evidences of
burns abrasions or other flaws
because they may become
unrecognizable after washing. Replace
if necessary.
(2) Immerse the disassembled parts in
the nonflammable solvent A (. Remove
them from the solvent and blow
compressed air B against them.
Scrape off foreign matters, if any, using
a plastic scraper C before the
immersion.
17
ENGINE – Turbocharger
DISASSEMBLY AND REASSEMBLY
INSPECTION
CARTRIDGE ASSEMBLY INSPECTION
(1) Axial play of the shaft Install the
cartridge assembly 8 temporarily in the
turbine housing 4, and measure the
axial play of the shaft by moving the
compressor wheel *2 in the axial
direction. If the reading deviates from
the specified standard value, replace
the cartridge assembly 8.
(2) Turbine wheel back to turbine back
plate clearance Install the cartridge
assembly 8 temporarily in the
compressor cover 6, and read the
clearance using a feeler gauge A.
If the measurement deviates from the
specified standard value, replace the
cartridge assembly 8.
Caution: .Be sure to measure the
clearance at the blade tips using two
feeler gauges.
18
ENGINE – Turbocharger
DISASSEMBLY AND REASSEMBLY
REASSEMBLY SERVICE POINTS
O-RING INSTALLATION
(1) Apply a thin coat of engine oil evenly to the entire circumferential surface of a-
ring before installing it.
SNAP RING INSTALLATION
(1) Install the snap ring 5 in the
compressor cover 6 with the tapered
surface A facing upward.
Caution:. Hold the snap ring 5 with
one hand not to let it bounce out.
COUPLING INSTALLATION
(1) Install the coupling 3 with the clip
side A positioned as shown.
19