Published: 10-Jun-2011

Fuel Charging and Controls - Turbocharger - TD4 2.2L Diesel -

Turbocharger - Component Location
Description and Operation

COMPONENT LOCATION

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Item Description
A Intake air from air filter
B Compressed air to charge air cooler
C Exhaust gas inlet
D Exhaust gas outlet
1 Oil supply pipe
2 Compressor housing
3 Rotary Electronic Actuator (REA)
4 Variable vane actuator linkage
5 Turbine housing
6 Exhaust manifold
7 Coolant supply pipe
8 Oil return pipe
9 Turbocharger support bracket
10 Coolant return pipe
 Published: 13-Jun-2011
Fuel Charging and Controls - Turbocharger - TD4 2.2L Diesel -
Turbocharger - Overview
Description and Operation

OVERVIEW
The variable vane turbocharger, fitted to the exhaust manifold, makes it possible to vary the exhaust gas flow of the
turbine, dependent on engine operation. This improves the power transfer to the turbine wheel and compressor, particularly
at low engine speeds, thus increasing the boost pressure. The guide vanes are opened progressively as the engine speed
increases so that the power transfer always remains in balance with the required charger speed and the required boost
pressure level. Variable vanes facilitate better use of the exhaust gas energy so as to further improve the efficiency of the
turbocharger and thus of the engine, compared to the more conventional 'wastegate control'.

A coolant pipe with a banjo type fixing is attached between the RH (right-hand) side of the cylinder block, EGR (exhaust
gas recirculation) inlet hose and the back of the turbo. The pipe feeds coolant around the turbocharger bearing housing to
assist with bearing cooling. A heat shield is installed over the turbocharger and exhaust manifold to protect other
components, and to prevent accidental contact with the hot exhaust components.

Advantages:

High torque at both high and low engine speeds

Continuous and optimum adjustment for all engine speeds
No wastegate valve required, exhaust energy is better utilized, less back-pressure in conjunction with same
compressor work
Low thermal and mechanical load improves engine power output
Lower emissions
Optimized fuel consumption over the entire engine speed range

A DC (direct current) rotary actuator motor operates a drive shaft. The drive shaft is connected to the vanes by an

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actuating lever. Adjustment of the vanes is achieved by moving the actuating lever. W hen the drive shaft is turned, a
signal is created at the end of the drive shaft; this feedback signal is used to determine the angular position of the vanes.
This information is transmitted to the ECM (engine control module).

The turbocharger is designed for fail safe operation. If a fault occurs regarding the control of the unit, the vanes default to
the fully open position so as to produce minimum boost. The ECM detects any malfunctions in the stepper motor and
generates DTC (diagnostic trouble code).
 Published: 13-Jun-2011
Fuel Charging and Controls - Turbocharger - TD4 2.2L Diesel -
Turbocharger - System Operation and Component Description
Description and Operation

Control Diagram
Turbocharger Operation

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Item Description
A Low engine speed
B Moderate engine speed
C Maximum engine speed
1 ECM (engine control module)
2 Actuator motor
3 Adjusting ring
4 Vanes
5 Turbine

System Operation
Principles of Operation
The turbocharger uses the energy of the exhaust gas flow from the engine to provide compressed (charged) air to the
intake air system. The variable geometry vanes make sure the turbocharger produces the required level of intake air boost
pressure for the current engine operating conditions.

The turbocharged engine provides the following advantages over a conventional naturally aspirated engine:

Greater volumetric efficiency

Improved engine power and torque
Reduced fuel consumption
Reduced emissions
Re-use of exhaust gas energy
Un-affected by altitude
Limited periods of over-boost for immediate engine demands.
In response to signals from various sensors, the ECM controls the REA to operate the rotary adjusting ring. Movement of
the adjusting ring alters the pitch angle of the variable vanes to deflect the flow of exhaust gas onto the inside center or
outside edge of the turbine wheel.

The maximum position of the turbocharger variable vanes (fully open) is also the emergency default position in the event
of an electrical fault. The REA will move the variable vanes to the fully open position to prevent engine damage due to
excessive boost pressure.

A - Low Engine Speed

At low engine speeds the volume of exhaust gas is low so the vanes are moved towards the closed position to reduce the
turbine inlet area. This reduction causes an increase in the gas velocity into the turbine wheel thereby increasing wheel
speed and boost.

B - Moderate Engine Speed

As the engine speed increases and the volume of exhaust gas increases so the vanes are moved towards the open position
to increase the turbine inlet area and maintain the gas velocity.

C - Maximum Engine Speed

At maximum engine speed the vanes are almost fully open maintaining the gas velocity into the turbine wheel.

Component Description
Over-Boost Pressure
During periods of medium to hard acceleration, the turbocharger is required to produce a limited period of over-boost
pressure from the compressor to meet the current engine fueling requirement. The ECM will request and allow the REA to
move the variable vanes toward the closed position to increase the velocity of the already high-speed turbine wheel. The
over-boost condition is allowed by the ECM for the limited period.

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Barometric Pressure Sensor
When the vehicle is driven at high altitudes the ambient pressure reduces causing the compressor wheel to do more work
for the same boost pressure. To prevent the turbine wheel from over-speeding under these conditions a barometric
pressure sensor, located in the ECM, protects the turbocharger by opening the vanes further to reduce the turbine wheel
speed. This is known as the altitude margin of the turbocharger.

Turbocharger Lubrication
The rapid acceleration and deceleration response demands of the turbocharger rely greatly on a steady flow of clean oil.
The oil supplied from the engine's lubrication system provides lubrication to the turbocharger's spindle and bearings, while
also acting as a coolant for the turbocharger center housing.

To maintain the life expectancy of the turbocharger, it is essential that the oil has a free-flow through the turbocharger and
unrestricted return to the engines sump. It is therefore imperative that the engine oil is replenished at regular service
intervals with the recommended quality and quantity of oil.

Charge Air Cooler

The charge air cooler is used to increase the density of air as it flows from the turbocharger compressor to the intake
manifold.

Compression of the charge air by the turbocharger raises the temperature of the air. This generation of heat expands the
air density and consequently less oxygen is able to enter the cylinders, reducing the engines power. To overcome this, the
air is routed through the charge air cooler before it enters the engine; the temperature is reduced by transferring the heat
to atmosphere.

Cooling of the intake air also helps to reduce engine emissions by limiting nitrogen oxides (NOx) production.

Turbocharger Cooling
The turbocharger receives an oil supply for lubrication and cooling purposes.

In addition to the cooling provided by the engine lubrication system, the turbocharger also requires a supply from the
engine coolant system to assist with the cooling due to the high loads on the turbocharger.

A pipe connection from the cylinder block routes engine coolant through the body of the turbocharger bearing housing.
Once the coolant has passed through the bearing housing it is returned to the cooling system.
 Published: 28-Jul-2011
Fuel Charging and Controls - Turbocharger - TD4 2.2L Diesel -
Turbocharger
Diagnosis and Testing

Principles of Operation
For information on the operation of the system, refer to the Fuel Charging and Controls section in the workshop manual.
REFER to: (303-04B Fuel Charging and Controls - Turbocharger - TD4 2.2L Diesel)

Turbocharger (Description and Operation),

Turbocharger (Description and Operation),
Turbocharger (Description and Operation).

Inspection and verification

WARNING: The following tests may involve working in close proximity to hot components. Make sure adequate
protection is used. Failure to follow this instruction may result in personal injury.

CAUTION: Diagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of control modules does
not guarantee confirmation of a fault and may also cause additional faults in the vehicle being checked and/or the donor
vehicle.

NOTE: Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.

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1. Verify the customer concern.

2. Visually inspect for obvious mechanical or electrical faults.

Visual inspection chart

Mechanical Electrical
Intake air system Circuit(s)
Hose(s)/hose connections Engine control module (ECM)
General engine condition Electrical connections and harnesses

3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding
to the next step

4. Use the approved diagnostic system or a scan tool to retrieve any diagnostic trouble codes (DTCs) before moving
onto the symptom chart or DTC index.
Make sure that all DTCs are cleared following rectification

Symptom chart

Symptom Possible source Action

Poor Low/Contaminated Check the fuel level and condition. Check the air intake for restriction. Check
performance fuel the engine condition, compressions, etc. Refer to the relevant section of the
Restricted air intake workshop manual. Check for DTCs. Refer to the warranty policy and procedures
system manual, or determine if any prior approval programme is in operation, prior to
General engine the installation of a new module/component
condition
Turbocharger failure

No boost Electrical connections Check the electrical connections and harnesses. Check the air intake for
and harnesses restriction/leakage (see visual inspection). Refer to the warranty policy and
Restricted air intake procedures manual, or determine if any prior approval programme is in
system operation, prior to the installation of a new module/component
Charge air cooler
restricted/leaking
Turbocharger failure

DTC index
For a complete list of all Diagnostic Trouble Codes (DTCs) that could be logged on this vehicle, please refer to Section
100-00.
REFER to: Diagnostic Trouble Code (DTC) Index - TD4 2.2L Diesel, DTC: Engine Control Module (PCM) (100-00 General
Information, Description and Operation).
 Published: 16-May-2013
Fuel Charging and Controls - Turbocharger - TD4 2.2L Diesel -
Turbocharger
Removal and Installation

Removal

WARNING: Observe due care when working near a hot exhaust system.

CAUTION: Make sure that all openings are sealed. Use new blanking caps.

NOTE: Some variation in the illustrations may occur, but the essential information is always correct.

1. Refer to: Front Subframe (502-00 Uni-Body, Subframe and Mounting

System, Removal and Installation).

2. Refer to: Exhaust Gas Recirculation (EGR) Cooler (303-08A Engine

Emission Control - TD4 2.2L Diesel, Removal and Installation).

3.

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4. NOTE: Diesel Particulate Filter shown. Non Diesel
Particulate Filter similar.
5.

6.

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7. NOTE: Discard the sealing washers.
 8.

9. NOTE: Loosen but do not remove the 2 retaining

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nuts.

10. WARNING: Make sure to support the vehicle with axle stands.

Raise and support the vehicle.

11.

12. NOTE: Remove and discard the gasket.

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13.
 14. NOTE: Remove and discard the gasket.

15. CAUTIONS:

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Discard the studs.

Discard the nuts.

NOTE: Remove and discard the gasket.

Installation
1. CAUTIONS:

Install new studs.

Make sure that new nuts are installed.

NOTE: Install a new gasket.

2. CAUTION: Make sure that the mating faces are

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clean and free of foreign material.

NOTE: Install a new gasket.

Torque:
M6 10 Nm
M12 29 Nm

3. CAUTIONS:

Make sure that the mating faces are clean and

free of foreign material.

Make sure that a new bolt is installed.

Only tighten the bolt finger-tight at this stage.

4. CAUTION: Make sure that a new bolt is installed.

Torque: 24 Nm

5. Torque: 24 Nm

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6. CAUTIONS:

Make sure that the area around the component is

clean and free of foreign material.

Make sure that new sealing washers are installed.

Torque: 21 Nm
7. Torque: 24 Nm

8. CAUTION: Make sure that the area around the

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component is clean and free of foreign material.

NOTE: Install a new gasket.

Torque: 10 Nm

9.
10. Torque: 10 Nm

11.

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12. NOTE: Diesel Particulate Filter shown. Non Diesel
Particulate Filter similar.

Torque: 10 Nm
 13. Torque:
M8 25 Nm
M6 10 Nm

14. Refer to: Exhaust Gas Recirculation (EGR) Cooler (303-08A Engine
Emission Control - TD4 2.2L Diesel, Removal and Installation).

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15. Refer to: Front Subframe (502-00 Uni-Body, Subframe and Mounting
System, Removal and Installation).

16. Check and top-up the engine oil.

17. If a new component has been installed, configure using Land Rover
approved diagnostic equipment.
 Published: 02-Jul-2011
Fuel Charging and Controls - Turbocharger - TD4 2.2L Diesel -
Torque Specifications
Description Nm lb-ft
Turbocharger studs 10 7
Turbocharger coolant feed pipe:
M6 10 7
M12 29 21
Turbocharger nuts and bolts* 24 18
Turbocharger oil feed banjo bolt 29 21
Turbocharger oil return pipe 10 7
Turbocharger heatshield retaining bolts 10 7
* New nuts/bolts must be installed

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