FUSO 4M4 – INTAKE AND EXHAUST – ON-VEHICLE INSPECTION AND ADJUSTMENT – Measurement and Adjustment of Turbocharger Boost Pressure

1.1 Preparation
• Remove the safety plug from the high voltage battery box while referring to Gr18 HEV System.
(Be sure to observe the regulations of your country or region regarding the qualifications or trainings required for servicing the high-voltage equipment.)
• Shift the transmission to neutral.
• Hold the steering wheel in neutral position.
• Turn off lamps and accessory devices not to increase the engine speed.
• Connect the Multi-Use Tester. (See Gr00.)
• If any fault exists (corresponding diagnosis code is issued), rectify it.

1.2 Measurement and correction of boost pressure
• Warm up the engine until the engine coolant has been heated to more than 70°C. (Determine coolant temperature from service data [13: Water temperature].)
• Check that the non-load minimum speed (idling speed) is as specified. (See Gr13.)
• Select [A5: VGT1] in [Actuator Test] of the Multi-Use Tester. Set [Target Value] to 70% and execute.
• When [A5: VGT1] is executed, the engine speed should be automatically increased to 2000 rpm.
• Maintain the state of [Target Value] having been executed (10 minutes or more) until boost pressure is stabilized.
• Measure the following items from among [Service Data].
0C: Boost pressure (measured boost pressure)
15: Atmospheric pressure (measured atmospheric pressure)
• Measure the intake air temperature (ambient temperature around the vehicle) using a thermometer.
• Obtain boost pressure correction value respectively by calculating above Service Data.
[Calculation of intake air temperature correction value]
• Intake air temperature correction value = –0.12 (Measured boost temperature –25)
[Calculation of atmospheric pressure correction value]
• Atmospheric pressure correction value = Measured atmospheric pressure –100
[Calculation of boost pressure correction value]
• Boost pressure correction value = Measured boost pressure – intake air temperature correction value – atmospheric pressure correction value
• If boost pressure correction value deviates from the standard value, adjust the turbocharger.

1.3 Turbocharger adjustment
• Adjust the turbocharger using the flowchart shown below.

[Inspection]
• Check whether the control crank comes into contact with the position bolt in accordance with the procedure described below.
– Place the starter switch in the “ON” position, and check to confirm that the turbocharger actuator shaft moves once to the full stroke position. At this time, put a thin paper between the control crank and position bolt to check for contact condition between them.
• If they are in contact, make adjustments in accordance with the procedures described in (1) below. If not, make adjustments in accordance with the procedures described in (2) below.

[Adjustment]
(1) When control crank and position bolt are in contact (normal condition)
(1.1) Adjustment of position bolt length
• Place the starter switch in the “LOCK” position or remove the starter key.
• Loosen the lock nut at.
• Provide alignment markings on the position bolt and turbocharger actuator unit with a pen or the like as shown in the illustration.
• Insert a hex wrench into the position bolt as shown and turn the bolt with it to adjust the boost pressure to the standard value.
• To increase boost pressure: Turn the position bolt clockwise (loosening direction).
• To decrease boost pressure: Turn the position bolt counterclockwise (tightening direction).
• Change in pressure: An increase of approximately 3 kPa per turn of the position bolt (with the measurement of boost pressure)
• After adjustment, tighten the lock nut of position bolt.

(1.2) Adjustment of turbocharger actuator shaft length
• This adjustment must be performed only when diagnosis code P2263 is generated or when the control crank does not contact the position bolt.
• Place the starter switch in the “LOCK” position or remove the starter key.
• Provide alignment markings on the lock nut of turbocharger actuator and joint with a pen or the like as shown in the illustration.
• Remove the snap ring and pin from the turbocharger actuator.
• Loosen the lock nut and turn the joint to extend the shaft.
• Guide to adjustment:
The shaft length must be changed only by the same amount as the position bolt adjustment made in the paragraph “(1.1) Adjustment of position bolt length”. (The amount of the turbocharger actuator stroke must not be changed.) The shaft length will change 1 mm by each one turn of the joint.
• The shaft length shall be considered normal if diagnosis code P2263 is not generated and the contact between the control crank and position bolt is observed even if it has not been adjusted by the same amount as for the position bolt.
• After adjustment, fit the snap ring and pin onto the turbocharger actuator, and tighten the lock nut.

(1.3) Measurement of boost pressure
• For measurement of the boost pressure, see “1.2 Measurement and correction of boost pressure.”
(1.4) Replacement of turbocharger
• For replacement of the turbocharger, see “TURBOCHARGER.”

(2) When the control crank does not come into contact with the position bolt
(2.1) Adjustment of turbocharger actuator shaft length
• Place the starter switch in the “LOCK” position or remove the starter key.
• Put an alignment mark on the lock nut and the joint of the turbocharger actuator with a pen or the like as shown in the illustration.
• Remove the snap ring and the pin on the turbocharger actuator side.
• Loosen the lock nut and turn the joint section. Place the starter switch in the “ON” position. Pull out the turbocharger actuator shaft to the length in which the control crank will contact the position bolt when the shaft is extended temporarily to its full stroke position.
Guide to adjustment:
The shaft length will change 1 mm by each one turn of the joint.
• Replace the lever and pin with new ones if the correct contact is not achieved even when the shaft is pulled out to the limit.
• Upon completing the shaft adjustment, install the snap ring and the pin on the turbocharger actuator side and tighten the lock nut.

(2.2) Measurement of boost pressure
• For measurement and of boost pressure, see “1.2 Measurement and correction of boost pressure”.

(2.3) Adjustment of the position bolt length
• This adjustment should be performed only when the boost pressure is not within the standard value range.
• Put an alignment mark on the position bolt and the turbocharger actuator body using a pen or the like as shown in the illustration.
• Loosen the lock nut of the position bolt using.
• Fit a hex wrench onto the position bolt as shown in the illustration and turn the bolt such that the measured boost pressure meets the standard value.
• To increase the boost pressure:
Turn the position bolt clockwise as shown in the illustration.
• To decrease the boost pressure:
Turn the position bolt counterclockwise as shown in the illustration.
• Guide to adjustment:
The boost pressure will change approximately 3 kPa each time the position bolt is turned one turn (when taking measurements of boost pressure).
• After adjustment, secure the lock nut with.

(2.4) Adjustment of turbocharger actuator shaft length
• This adjustment must be performed only when diagnosis code P2263 is generated or when the control crank does not contact the position bolt.
• Place the starter switch in the “LOCK” position or remove the starter key.
• Provide alignment markings on the lock nut of turbocharger actuator and joint with a pen or the like as shown in the illustration.
• Remove the snap ring and pin from the turbocharger actuator.
• Loosen the lock nut and turn the joint to extend the shaft.
• Guide to adjustment:
The shaft length must be changed only by the same amount as the position bolt adjustment made in the paragraph “(1.1)
Adjustment of position bolt length”. (The amount of the turbocharger actuator stroke must not be changed.) The shaft length will change 1 mm by each one turn of the joint.
• The shaft length shall be considered normal if diagnosis code P2263 is not generated and the contact between the control crank and position bolt is observed even if it has not been adjusted by the same amount as for the position bolt.
• After adjustment, fit the snap ring and pin onto the turbocharger actuator, and tighten the lock nut.

(2.5) Measurement of boost pressure
• For measurement of the boost pressure, see “1.2 Measurement and correction of boost pressure.”
(2.6) Replacement of turbocharger
• For replacement of the turbocharger, see “TURBOCHARGER.”

 

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