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 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


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



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



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



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



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


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


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


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


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 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


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



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



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



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



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

worksheet turbo

Documents

mating marks

turbine wheel

turbine wheel

exhaust specifications

engine turbocharger

compressor

turbine wheel

cartridge