CATALYST AND TURBOCHARGER ZD
Removal and Installation (Cont’d)
2. Remove catalyst.
CAUTION:
Do not disassemble catalyst.
3. Remove oil feed tube and oil return tube.
4. Remove turbocharger.
CAUTION:
Turbocharger must not be disassembled.
Inspection
TURBOCHARGER
SEM766G
CAUTION:
When the compressor wheel, turbine wheel, or rotor shaft is
damaged, remove all the fragments and foreign matter left in
the following passages in order to prevent a secondary failure:
Suction side: Between turbocharger and intake mani-
fold
Exhaust side: Between turbocharger and catalyst
NOTE:
Figures which follow are intended to explain inspection pro-
cedures. (Shapes of parts may differ from those of actual
parts.)
EM-96
CATALYST AND TURBOCHARGER ZD
Inspection (Cont’d)
Rotor shaft
I Check that the rotor shaft rotates smoothly without any resis- GI
tance when it is rotated by your fingertips.
I Check that the rotor shaft is not loose when it is moved verti-
cally or horizontally. MA
SEM798C LC
Rotor shaft end play
Place a dial gauge at the rotor shaft end in the axial direction to EC
measure the end play.
Standard: 0.002 - 0.006 mm (0.0001 - 0.0002 in)
FE
CL
MT
SEM801C
Turbine wheel
AT
I Check that there is no oil adhesion.
I Check that there is no carbon accumulation.
I Check that blades of the turbine wheel are not bent or broken. TF
I Check that the turbine wheel does not interfere with the turbine
housing.
PD
FA
SEM802C
Compressor wheel RA
I Check that there is no oil adhesion inside the air inlet.
I Check that the compressor wheel does not interfere with the
compressor housing. BR
I Check that the wheel is not bent or broken.
ST
RS
SEM803C
WASTEGATE VALVE BT
Remove rod pin and check wastegate valve for cracks, deformation
and smooth movement. HA
Check valve seat surface for smoothness.
EL
IDX
SEM804C
EM-97
CATALYST AND TURBOCHARGER ZD
Inspection (Cont’d)
WASTEGATE VALVE ACTUATOR
Apply air pressure to wastegate valve actuator and check it for
smooth movement.
I Do not keep applying air pressure to the actuator.
I The air pressure should be in the range of 142.3 to 147.7
kPa (1.42 to 1.48 bar, 1.451 to 1.507 kg/cm2, 20.7 to 21.4
psi).
Standard value for actuator rod operating pressure
[when stroke is 1.5 mm (0.059 in)]:
142.3 - 147.7 kPa (1.42 - 1.48 bar, 1.451 - 1.507
SEM805C kg/cm2, 20.7 - 21.4 psi)
EM-98
CATALYST AND TURBOCHARGER ZD
Inspection (Cont’d)
Trouble diagnosis of turbocharger
Preliminary check: GI
I Check that the engine oil level is between MIN and MAX of the
dipstick. (When the engine oil amount is more than MAX, the
oil flows into the inlet duct through the blow-by gas passage, MA
and the turbocharger is misjudged failure.)
I Ask the customer if he/she always runs the vehicle in idle
engine speed to cool the oil down after driving.
I Replace the turbocharger assembly when any malfunction is
found after unit inspections specified in the table below.
I If no malfunction is found after the unit inspections, judge that LC
the turbocharger body has no failure. Check the other parts
again.
EC
Symptom (when each inspection item
meets each inspection result)
FE
Insuffi-
Inspection item Inspection result cient
Oil leak-
Smoke Noise
power/ CL
age accel-
eration
failure MT
Oil leaks. g g g
Carbon is accumulated. g q q
Turbine wheel AT
Friction with housing. g q q
Blades are bent or broken.
TF
Inside the air inlet is seriously contami-
q q
nated by oil.
Compressor wheel PD
Friction with housing. g q q
Blades are bent or broken.
There is resistance when the rotor shaft
g g q
FA
is rotated by your fingertips.
After checking both turbine and compressor,
The rotor shaft sometimes does not
inspect rotor shaft end play.
rotate by your fingertips.
RA
There is too much play in the bearing. g g q g
Carbon or sludge is accumulated in the BR
Oil return port g g g
waste oil hole.
I Valve does not open smoothly when ST
inspection pressure is gradually
Wastegate valve operation applied.
I Valve does not close smoothly when RS
inspection pressure is removed.
: Large possibility
q: Medium possibility BT
g: Small possibility
INSTALLATION
1. Install turbocharger.
HA
I For direction of gasket installation, refer to “Removal and
Installation”, EM-95.
2. Install oil feed tube and oil return tube.
EL
3. Install catalyst.
4. Install in the reverse order of removal. IDX
EM-99
