INTAKE AND EXHAUST Specifications GENERAL SPECIFICATION (4D56) Items Air Filter Type Element Exhaust System Front

t Exhaust Pipe 4D56 Muffler Coupling Turbocharger Type Identification Number Supercharging Pressure Control Intercooler Type SERVICE SPECIFICATIONS Items Intake And Exhaust Manifold Distortion of Cylinder Head Contacting Surface mm (in) Turbocharger Initial Starting pressure of waste gate actuator kPa (kg/cm. psi) 91 (0.91, 13) Less Than 0.15 (0.0059) 0.3 (0.012) Standard Limit Air Cooled Type Exhaust Gas Turbine Type TD04-11G-4 Waste Gate Actuator Single Type Expansion Resonance Type Spherical Coupling and Flat Coupling Dry Type Unwoven Cloth Type Specifications

INTAKE AND EXHAUST Specifications INTAKE AND EXHAUST MANIFOLDS

Remove And Installation

Removal Steps
1. Intake Fitting 2. Intake Fitting Gasket 3. Air Hose 4. Boost Hose 5. Waste Gate Actuator 6. Heat Protector B 7. Stay 8. Heat Protector B 9. Heat Protector C 10. Exhaust Fitting 11. Exhaust Fitting Gasket 12. Eyebolt 13. Gasket 14. Oil Pipe 15. Oil Hose 16. Oil Return Pipe 17. Gasket 18. Turbocharger Assembly 19. Gasket 20. Intake manifold 21. Engine Hanger 22. Exhaust manifold 23. Exhaust Manifold Gasket

ENGINE Turbocharger DISASSEMBLY AND REASSEMBLY

Disassembly Step
1. 2. 3. 4. 5. 6. 7. 8. Hose Clip Hose Coupling Turbine Housing Snap Ring Turbine Wheel Assembly Compressor Cover O.Ring

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.

ENGINE Turbocharger SERVICE POINT OF DISASSEMBLY

REMOVAL ASSEMBLY (1)

OF

TURBINE

WHEEL

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, and other pitching, damage. deformation cracked. (2) Operate the waste gate valve lever manually to check that the gate can be opened and closed smoothly. ENGINE Turbocharger SERVICE POINT OF DISASSEMBLY

Replace with a new turbine housing if

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. 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. 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.

ENGINE Turbocharger SERVICE ADJUSTMENT PROCEDURE 8

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 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 make reading of the measurement values on the pressure

(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 ENGINE Turbocharger SERVICE ADJUSTMENT PROCEDURE 9

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 pressure 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.

ENGINE Turbocharger REMOVAL AND INSTALLATION

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Removal Steps
1. 2. 3. 4. 5. Air Temperature switch connector Intercooler fan motor connector Air hose B connection (Intake Side) Air Hose A-1 Connection (Turbocharger Side) Intercooler and Bracket assembly

6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.

Air Hose A-1 Blanch Hose Blanch Pipe Joint Blanch Pipe Blanch Pipe Bracket Intercooler cover Air Hose A-2 Air Hose B Air Temperature Switch Bracket Fan Motor Intercooler

ENGINE Intercooler

11

INSPECTION Check the intercooler fins for bending damage or foreign matter. Check the intercooler hoses for cracking. Damage or wear. CHECKING SWITCH (1) Immerse the air temperature switch in the hot water shown in the figure. (2) When changing check for the water AIR TEMPERATURE

temperature. tester.

continuity

between the terminals with the circuit

INTAKE AND EXHAUST Specifications GENERAL SPECIFICATION (4M40) Items Specifications 12

Air Filter Type Element Exhaust System Front Exhaust Pipe 4D56 Muffler Coupling Turbocharger Type Supercharging Pressure Control Intercooler Type SERVICE SPECIFICATIONS Items Turbocharger Actuator Operating Pressure When Operated 1mm (0.04 in) Cartridge Assembly Axial Play Of Shaft Turbine Wheel Back to Turbine Back Plate Clearance 0.057 0.103 0.39 0.83 91 (0.91) Standard Limit Air Cooled Type Exhaust Gas Turbine Type Waste Gate Actuator Single Type Expansion Resonance Type Spherical Coupling and Flat Coupling Dry Type Unwoven Cloth Type

INTAKE AND EXHAUST Specifications INTAKE AND EXHAUST MANIFOLDS

13

Remove And Installation

1. Eyebolt 2. Oil feed Pipe 3. Oil Return Pipe 4. Nut 5. Coupler Insulator 6. Insulator

7. Coupler 8. Gasket 9. Nut 10. Bolt 11. Insulator B 12. Insulator A

13. Gasket 14. Turbocharger Assembly * Exhaust Manifold * Turbocharger water outlet pipe * Turbocharger water inlet pipe

ENGINE Turbocharger INSTALLATION SERVICE POINT 14

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.

ENGINE Turbocharger DISASSEMBLY AND REASSEMBLY 15

Disassembly Steps
1. 2. 3. 4. 5. 6. 7. 8. *1 *2 Hose Actuator Coupling Turbine Housing Snap Ring Compressor Cover O-Ring Cartridge Assembly Turbine Wheel 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.

ENGINE Turbocharger DISASSEMBLY AND REASSEMBLY

16

COMPRESSOR COVER REMOVAL Caution: circumferential Tap allover surface of the 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 because if necessary. (2) Immerse the disassembled parts in the nonflammable solvent A (. Remove them from compressed a plastic the solvent and blow air B against C before them. the abrasions they or other flaws become may

unrecognizable after washing. Replace

Scrape off foreign matters, if any, using scraper immersion.

ENGINE Turbocharger DISASSEMBLY AND REASSEMBLY INSPECTION 17

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.

ENGINE Turbocharger DISASSEMBLY AND REASSEMBLY

18

REASSEMBLY SERVICE POINTS O-RING INSTALLATION (1) Apply a thin coat of engine oil evenly to the entire circumferential surface of aring 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.

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