Vehicle check
1. Checking the intake system.
Check the condition of the air filter and air duct. Replace if necessary. Eliminate any leaks in the connections.
2. Check the condition of the exhaust system for:
- deformations of parts;
- foreign objects in the channels;
- cracks.
3. Check boost pressure.
A) Warm up the engine.
b) Install a pressure gauge in the break in the boost pressure corrector hose of the injection pump.
L series engines
Engine 1KZ-T
V) (2L-T) Disengage the clutch and depress the accelerator pedal sharply. Measure boost pressure at 2400 rpm (or higher).
Pressure - 0.61-0.81 bar
G) (1KZ-T) Press the clutch pedal and bring the engine to 4600 rpm. Measure the boost pressure.
Pressure - 0.51 - 0.67 bar
If the pressure is less than the regulated one, check the tightness of the intake and exhaust systems. If there are no leaks, replace the turbocharger.
If the pressure is more than the regulated one, check the condition of the vacuum hose of the bypass valve actuator.
If the hose is OK, replace the turbocharger.
4. Check the rotation of the compressor wheel.
A) Disconnect the air cleaner hose.
Parts for removal and installation (2L-T): 1 - air inlet, 2 - heat shield #1, 3 - heat shield #2, 4 - gasket, 5 - heat shield #3, 6 - outlet, 7,10,11,12,14 - gasket, 8 - turbocharger, 9 - exhaust manifold support, 13 - turbocharger cooling system pipes, 15 - oil supply pipe, 16 - oil drain hose.
b) Turn a wheel for a fastening nut. If the wheel does not turn or rotates with effort, replace the turbocharger.
Removing the turbocharger
1. Drain the engine coolant.
L series engines
2. Remove the intake duct.
A) Disconnect the vacuum hoses from the boost corrector.
b) Loosen the duct clamp bolts.
V) Remove the three nuts, intake manifold and gasket.
3. Disconnect water hoses.
4. Remove heat shields (four bolts and three nuts).
5. Remove the exhaust manifold bracket.
6. Turbocharger lubrication system.
A) From the cylinder block, remove the oil feed pipe banjo banjo bolt and remove the two seal washers.
b) Disconnect the oil drain hose.
V) Unscrew the two nuts and remove the oil supply pipe and gasket from the turbocharger.
7. Remove the turbocharger from the exhaust manifold by removing the four nuts.
Parts for removal and installation (1KZ-T):1 - gasket, 2 - air intake duct, 3 - hose, 4 - exhaust manifold heat shield, 5 - turbocharger heat shield, 6 - outlet pipe (turbines), 7 - rack, 8 - inlet pipe (compressor), 9 - turbocharger, 10 - turbocharger cooling hoses, 11 - turbocharger cooling pipes, 12 - exhaust manifold, 13 - turbocharger oil drain pipe.
8. Remove the water tube from the turbocharger.
9. Remove the outlet (four nuts) and padding.
Engine 1KZ-T
2. Remove the intake duct.
A) Disconnect the vacuum hoses from the boost corrector and the vacuum switch.
b) Disconnect the wire clamps.
V) Loosen the four nuts and remove the sealing washers.
G) Disconnect the two crankcase ventilation hoses.
d) Use pliers to bring the ends of the clamp together until the clamp latch is disengaged.
e) Remove the air duct and gasket.
3. Turn away four nuts and remove the thermal screen TKR.
4. Turn away four nuts and remove the heat shield of a final collector.
5. Disconnect water hoses.
6. Turn away four nuts and remove a final branch pipe of the turbine and a lining.
7. Remove the turbocharger strut.
8. Removing the turbocharger and exhaust manifold.
A) From the cylinder block, unscrew the hollow nipple bolt of the oil supply pipe and remove the two sealing washers.
b) Remove the two bolts and disconnect the oil drain pipe.
V) Remove six nuts and two bolts, turbocharger, exhaust manifold and three gaskets.
9. Turn away two nuts and remove a tube of drain-supply of oil.
10. Turn away three nuts and remove a turbocharger from a final collector.
11. Turn away two nuts and a bolt, remove tubes of cooling from TKR.
12. Turn away two nuts and remove from TKR an inlet branch pipe of the compressor.
Turbocharger check
1. Check wheel rotation. Make sure the wheel spins smoothly. If the wheel does not rotate or rotates with resistance, replace the turbocharger.
2. Check the axial clearance of the compressor shaft.
Install the indicator on the compressor side, moving the turbine wheel by hand, measure the axial clearance.
Axial clearance:
- 2L-T - no more than 0.13 mm
- 1KZ-T - no more than 0.173 mm
If the axial clearance is out of range, replace the turbocharger.
3. Check the radial clearance of the compressor shaft.
A) Through the oil drain hole from the turbocharger, install the indicator on the compressor shaft.
b) By moving the shaft in the radial direction, measure the radial clearance.
Radial Clearance:
- 2L-T - no more than 0.18 mm
- 1KZ-T - no more than 0.11 mm
If the radial clearance is out of range, replace the turbocharger.
4. Checking the operation of the bypass valve actuator.
A) Disconnect the actuator diaphragm hose.
b) Create pressure over the diaphragm. The actuator stem must move. If not, replace the turbocharger.
Pressure:
- 1KZ-T - 1.18 bar
- 2L-T - 0.8 bar
Attention: never apply pressure to the diaphragm more than the limit.
Ultimate pressure:
- 1KZ-T - 1.27 bar
- 2L-T - 0.95 bar
Turbocharger Installation
Attention: after installing the turbocharger, fill 20 - 30 cm3 fresh oil into the bearing housing and rotate the compressor shaft by hand.
Engine - 2L-T
1. Install a new gasket and secure the outlet pipe with four nuts.
Tightening torque - 25 N.m
2. Install a new gasket and water tube with two bolts and nuts.
Tightening torque 8 N.m
3. Installing the turbocharger on the exhaust manifold.
A) Place a new gasket on the manifold.
b) Secure the turbocharger with four nuts.
Tightening torque 52 N.m
4. Install the oil pipe.
A) Install a new gasket and secure the oil supply pipe with two nuts.
Tightening torque 19 N.m
b) Connect the oil drain hose.
V) Replace the sealing washers and tighten the nipple bolt securing the oil supply pipe to the block.
Tightening torque 25 N.m
5. Install the outlet pipe bracket.
Mounting torque 19 N.m
6. Install the heat shield.
Tightening torque 12 N.m
7. Connect the water supply pipe.
8. Install the intake duct.
A) Install a new gasket and secure the air tube with three nuts.
Tightening torque 12 N.m
b) Connect the boost corrector vacuum hoses.
9. Fill the cooling system
10. Start the engine and check for leaks.
11. Check the oil level.
Engine 1KZ-T
1. Install a new gasket and secure the outlet with two nuts.
Tightening torque 19 N.m
2. Install a new gasket and coolant tube. Tighten bolts and nuts.
Torque:
- Bolts - 12 N.m
- Nuts - 8 N.m
3. Installing the turbocharger on the exhaust manifold.
A) Place a new gasket on the manifold.
b) Secure the turbocharger with three nuts.
Tightening torque 52 N.m
4. Install the oil supply-drain tube.
A) Install a new gasket and secure the oil supply pipe with two nuts.
Tightening torque 19 N.m
b) Connect the oil drain hose.
5. Installing the manifold and turbocharger on the engine.
A) Replace oil supply sealing washers and oil drain tube gasket.
b) Install a new manifold gasket.
V) Install the manifold with TKR by tightening the 6 nuts and two manifold mounting bolts.
Tightening torque - 52 N.m
G) Tighten the hollow bolt and two tube flange nuts.
Torque:
- Bolt - 26 N.m
- Nuts - 12 N.m
6. Install the TKR rack, tighten the fasteners
Tightening torque - 19 N.m
7. Install a new gasket and turbine outlet. Tighten the 4 fastening nuts.
Tightening torque - 39 N.m
8. Connect the water supply hoses.
9. Install exhaust manifold heat shield.
Tightening torque - 8 N.m
10. Install the TKR heat shield.
Tightening torque - 8 N.m
11. Installing the intake duct.
A) Install a new gasket on the intake manifold.
b) Install the air hose.
V) Squeeze the ends of the hose clamp and engage the latch of the clamp.
G) Connect two crankcase ventilation hoses
d) Install 4 sealing washers. Tighten the fastening nuts.
Tightening torque - 11 N.m
e) Secure the wires with two clamps.
and) Connect the vacuum shutoff valve connector and two vacuum hoses.
12. Fill the cooling system
13. Start the engine and check for leaks.
14. Check the oil level.