Description Necessity of Turbocharger and Supercharger

The turbocharger and supercharger are devices that

Turbocharger force air into the cylinders creating a pressure that is
greater than the atmospheric pressure in order to
increase engine output.
Generally, the engine output is determined by the amount
of the air-fuel mixture, burned over a specified period of
time, and becomes greater as the amount of the air-fuel
mixture increases.
That means in order to increase the engine output, either
the engine displacement or engine speed must be
increased.
The problem is that as engine displacement increases,
engine weight also increases and factors such as friction
loss, vibration and noise of moving parts limit the increase
of the engine speed.
Supercharger
The super charger meets the opposing requirements of
increasing engine output while keeping it compact and
lightweight by supplying greater volumes of air and fuel
without changing engine size.
The devices are driven by two methods: The turbo-
charger is driven by exhaust gas and the supercharger is
driven by the engine.
Toyota adopted the turbocharger in 1980, and the super-
charger in 1985 in Japan. Presently in 2002, only the tur-
bocharger is used in overseas models.
(1/1)

Features of Turbocharger and Supercharger

kPa
(kgf/cm2 ) Both the turbocharger and supercharger are a kind of air
98 pump, which force the air into the cylinder to increase the
(1.0) Turbocharger
mass of the intake air. The conventional engine draws air
in, using the vacuum generated when the piston goes
Boost pressure
down.
The pressure inside the intake manifold becomes higher
because the turbocharger or supercharger force the
Supercharger
intake air into the cylinders at a pressure (boost pressure)
higher than atmospheric pressure. Thus, the mass of the
Engine speed
rpm intake air into the cylinder is increased.

TURBOCHARGER SUPERCHARGER
Turbine Mechanical (roots type supercharger*
Type of charger
(turbine and compressor wheels) using one pair of cocoonshaped rotors)

Driving method Exhaust gas pressure Engine crankshaft drive

Small because turbocharger is driven by Large because supercharger is driven by

Power loss
exhaust gas pressure. crankshaft.

Small in low-speed ranges and large in

high-speed ranges.
Charging effect Charging is possible in all speed ranges.
(The causes are a small amount of exhaust
gases during low engine speed.)
Good response is obtained because
The response during low engine speed is
Response supercharger is directly driven by
not as good as that of the supercharger.
crankshaft.
*The roots type supercharger is the most common type in use at present.
(1/1)

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REFERENCE
Charging Efficiency
1. Charging efficiency
The engine's ability to draw air in is called charging efficiency.
The charging efficiency of a conventional engine is about 65-85% due to the resistance of the intake system and
the exhaust gas remaining in the exhaust system.
However the charging efficiency of an engine equipped with a turbocharger or supercharger can be more than
100%.
2. Compression ratio
The gasoline engine has a greater tendency of knocking as the compression pressure is increased.
Since air is compressed to a pressure greater than the atmosphere pressure and is fed to the cylinders of a tur-
bocharged or supercharged engine, the compression pressure becomes higher than that of the conventional
engine and knocking occurs more easily.
Therefore the compression ratio of a turbocharged or supercharged engine is set lower than that of a conven-
tional engine to prevent knocking.
Mass of air actually taken in
Charging efficiency(%) = X 100
Mass of air in cylinder under standard conditions*

*Standard conditions: Standard atmosphere pressure at 20 C(68 F)

(1/1)

Turbocharger Description
The turbocharger is a device which uses
Turbocharger
the energy of the exhaust gas to rotate
Turbine wheel the turbine wheel at high speeds. There
is a compressor wheel on the same
shaft as the turbine wheel which com-
Actuator
Compressor wheel presses air into the cylinders when it is
Air flow meter rotated.
Intercooler
In this way, engine output is increased.
Waste The waste gate valve and actuator pre-
gate
valve vent the boost pressure from rising too
high.
Turbo pressure sensor Some models are equipped with an
intercooler to lower the temperature of
the compressed intake air and improve
the charging efficiency ratio.
NOTICE:
Caution is necessary for handling vehi-
cles because the turbocharger becomes
extremely hot due to the exhaust gases.
Also, it is necessary to faithfully replace
the engine oil at the determined replace-
ment interval.
Refer to the “Precautions for Turbo-
charger” for more information.
(1/1)

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 Components
Full-floating bearings
Turbine wheel to Intake manifold The turbocharger consists of the turbine
Waste gate valve
housing, compressor housing, center
housing, turbine wheel, compressor
wheel, full-floating bearings, waste gate
valve, actuator, etc.
from Air cleaner

Compressor wheel
to Exhaust pipe

Actuator

from Exhaust Turbine housing

manifold
Center housing
Compressor housing

Waste gate valve

Actuator

Turbine and compressor wheels

The turbine wheel and compressor
wheel are mounted on the same shaft.
When the turbine wheel rotates at high
speed due to the pressure of the
Turbine wheel exhaust gas from the exhaust manifold,
the compressor wheel on the same shaft
Compressor wheel
also rotates, compressing the intake air
to
into the cylinder.
Exhaust The turbine wheel must be heat resistant
pipe
and durable because it is directly
exposed to the exhaust gas and
from becomes extremely hot and rotates at
Air
cleaner
high speeds. Therefore it is made of an
ultra-heat resistant alloy or ceramic.

from Exhaust to Intake

manifold manifold

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 Center housing
The center housing supports the turbine
Oil channel wheel and compressor wheel via the
shaft.
Coolant channel There is an oil channel in the housing to
Coolant channel
Oil channel
supply engine oil to lubricate and cool
the shaft and bearings.
Also, engine coolant is circulated
through the coolant channel that is built
into the housing in order to prevent the
engine oil temperature from rising and
the engine oil from deteriorating prema-
turely.

Shaft
Bearing Bearing

Shaft

Full-floating bearings
Since the turbine and compressor
Shaft wheels turn at speeds of up to 100,000
rpm, the full-floating bearings are used
to ensure the absorption of vibrations
from the shaft and lubrication of the shaft
and bearings.
The full-floating bearings are lubricated
by the engine oil and rotate freely
between the shaft and housing to reduce
friction, thus allowing the shaft to rotate
at high speed.

Full-floating bearing

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 Waste gate valve and actuator
The waste gate valve is built into the tur-
bine housing.
Turbine housing
The waste gate valve opens and
bypasses part of the exhaust gas to the
Turbine wheel
exhaust pipe in order to stabilize the
boost pressure when the boost pressure
Waste gate valve reaches the specified value, approx. 70
kPa (approx. 0.7 kg/cm2).
The opening and closing of the waste
gate valve are controlled by the actuator.
(1/1)

Compressor wheel

Actuator

REFERENCE
Exhaust gas control valve
Air cleaner
Two-way Twin Turbo
Two-way twin turbo features two turbo-
Waste gate valve chargers installed in one engine.
No.2 turbocharger
When the turbochargers are operated
No.1 turbocharger
efficiently under light loads or low speed,
Exhaust gas
bypass valve engine responsiveness such as acceler-
ation is improved. When the turbocharg-
ers are operated efficiently under heavy
load and high speed, high power output
can be attained.
Intercooler When there is only one turbocharger, it
is difficult to attain efficient operation for
Intake air control valve both heavy loads and light loads. In this
case it is only possible to attain effi-
ciency one way or the other.
However, the twin turbo controls the
exhaust gas control valve and exhaust
bypass valve. It operates one turbo-
charger under light loads, and two turbo-
chargers for high speeds and heavy
loads in order to improve engine
response in all speed ranges and attain
high power.
The illustration at left shows 2JZ-GTE
engine produced in 1993-1999.
(1/1)

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 1
How to Increase Fuel Injection Vol-
ume
An engine equipped with a turbocharger
or supercharger forces a greater volume
of air into the cylinder. The power output
does not increase until the intake air is
burned completely. For this reason, it is
necessary to increase the fuel volume to
burn the intake air completely. Thus, fuel
2
consumption will increase as the power
output is increased.
ECU
ECU

1. Mechanically controlled type

Turbine wheel With a diesel engine, the boost com-
Compressor wheel
pensator increases the maximum
to fuel injection volume in accordance
Exhaust from Air cleaner Boost compensator
pipe with the boost pressure. (Refer to the
Boost pressure
Waste (Compressed air) chapter of the diesel injection pump
gate
valve in the book of diesel engine, for
details.)

Actuator

Exhaust gas

Diesel injection pump

2. Computer-controlled type
Turbine wheel The computer-controlled engine
Compressor wheel detects the intake air volume with the
Air flow meter
air flow meter and the intake mani-
to from
Exhaust Air fold pressure with the turbo pressure
pipe cleaner
sensor, and increases the maximum
Waste Air flow meter
gate
Boost pressure
(Compressed air)
fuel injection volume with the engine
valve
ECU ECU. (The fuel injection volume is
determined by the injection duration.)
ECU
Although the illustration on the left
Actuator shows the diesel engine, the fuel
injection volume is increased in pro-
Turbo pressure
sensor
portion to the volume of the intake air
Exhaust gas
in a gasoline engine.
Injector
(1/1)
Diesel injection pump

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 Lubrication and Cooling System
from Oil inlet pipe
Coolant channel 1. Lubrication system
Engine oil is supplied from the oil
inlet pipe to lubricate and cool the
Oil inlet
pipe full-floating bearings inside the cen-
ter housing. After that, the oil passes
through the oil outlet pipe and returns
to the oil pan.

Oil outlet pipe

2. Cooling system
to Oil outlet Oil channel The turbocharger is cooled by the
pipe
engine coolant. The engine coolant is
Coolant outlet pipe Coolant inlet pipe Coolant channel introduced into the coolant channel
from
Thermostat
inside the center housing via the
housing coolant inlet pipe.
to Water The engine coolant returns to the
pump
water pump via the coolant outlet
pipe after cooling the turbocharger
Oil channel system.
(1/1)

to Oil outlet from Oil inlet

pipe pipe

Boost Pressure Control

Turbine wheel Compressor wheel
The turbocharger attains a high output
by pumping compressed air into the cyl-
inders. However engine parts will be
unable to withstand the explosive force if
the boost pressure rises too high.
to Exhaust pipe Intake air In this case, the waste gate valve is acti-
(from air cleaner)
vated by the actuator, and controls the
Waste gate valve boost pressure so that the boost pres-
sure does not rise above the specified
value.
to Combustion
Exhaust gas chamber
(from combustion chamber)

Actuator

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 1. Boost pressure control
(1) Control when the boost pressure is
below the specified value
When the boost pressure is below the
specified pressure, the actuator does
not operate. All the exhaust gas is there-
fore routed into the turbine wheel
because the waste gate valve remains
closed.

(2) Control when the boost pressure is

above the specified value
When the engine speed rises and the
boost pressure supplied by the turbo-
charger exceeds the specified value
(intercept point), the actuator dia-
phragm is depressed. This causes
the waste gate valve to open and
part of the exhaust gas bypasses the
turbine wheel.
By allowing part of the exhaust gas to
bypass the turbine wheel, the rota-
tional speed of the turbine wheel is
regulated so that the boost pressure
becomes within the specified value.
HINT:
With some gasoline engine, the
boost pressure is also controlled in
accordance with the octane rating of
the fuel used (premium or regular
gasoline).
(1/1)

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Waste gate valve opens
REFERENCE
Relationship between Boost Pressure and Engine
Speed
The relationship between the boost pressure and engine
speed when the accelerator pedal is fully depressed, is
shown on the left.
The relationship between the boost pressure and engine
speed varies according to the load placed on the engine.
(1/1)

Intercept point
Boost pressure

Engine speed

REFERENCE
Turbocharging Indicator Lights (Some Models Only)
3 1. Turbocharging indicator lights
2 ENGINE
4 The turbocharging indicator lights are built into the
1000r/min
1 combination meter, and inform the driver about oper-
5
ating condition of the turbocharger with green and
amber LEDs (Light-emitting diodes).
6
TURBO
When the turbocharger operates the specified boost
pressure, the green LED is turned on. The amber LED
Turbocharging Over-charging is turned on when the turbocharger exceeds the spec-
indicator light warning light
(green) (amber)
ified boost pressure.

2. Pressure switches
Two switches are used to sense boost pressure: Low-
Spring Diaphragm pressure switch and high-pressure switch.
The difference between these two switches is the
strength of the springs.
When the boost pressure applied to the diaphragm
Boost
pressure
exceeds a certain level, the switch is turned on.
(1/1)

Moving point Fixed point

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 Variable Nozzle Vane
The variable nozzle vane changes the
Step motor
flow speed and direction of the exhaust
gas to optimize boost pressure from low
speeds to high speeds using the engine
ECU to control the pitch of the nozzle
vane, which is mounted on the circum-
ference of the turbine.

Turbine wheel

Motor rod
Linkage
Unison ring
Nozzle vane

1. Operation
At low speed
Flow of the exhaust gas Step motor As the nozzle vane passage
becomes narrow (closes), the flow
speed of the exhaust gas flowing into
the turbine wheel becomes faster
and the turbine wheel operates more
efficiently. In this way, as the exhaust
gas pressure applied to the turbine
wheel is increased, the increase of
boost pressure becomes faster, and
engine output is increase even at low
Nozzle vane
speeds.
Turbine wheel

Motor rod
Unison ring
Linkage

At high speed/heavy load

As the nozzle vane passage
becomes wide (opens), the boost
Flow of the exhaust gas
Step motor pressure is controlled because the
flow direction of the exhaust gas
changes and the efficiency rate of
the exhaust gas, which is activated
on the turbine wheel, decreases.
However, the excess rotation of the
turbine wheel is prevented with
improvement of the fuel consumption
and engine output because the boost
Nozzle vane
pressure is controlled to the specified
Turbine wheel
pressure.
Unison ring Motor rod (1/1)
Linkage

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 Intercooler (Some Models Only)
The intercooler is mounted between the
Air-cooled type intercooler Air-cooled type intercooler
Vehicle wind stream compressor wheel and engine, and
Intercooler
operates to cool the intake air, which is
compressed by the turbocharger and
heated up.
Intercooler
Air temperature rises when compressing
Compressor wheel the air in the turbocharger. The charging
Intercooler
efficiency rate is lowered because the
Water-cooled type
intercooler
high-temperature air expands and it is
lowered. The intercooler increases the
air density by lowering the air tempera-
Compressor wheel ture and improves the charging effi-
ciency rate.
Sub-radiator
It also acts to control knocking.
Coolant
Electric water pump There are two types of intercoolers: The
air-cooled type and water-cooled type.
Only the air-cooled type intercooler is
used at present.
The intercooler is in different locations
depending on the model.
1. Air-cooled type intercooler
The air-cooled type intercooler uti-
lizes the vehicle wind stream or an
engine cooling fan to cool the com-
pressed air.
(1/1)

REFERENCE
to Air intake chamber Water-cooled Type Intercooler
Intercooler The water-cooled type intercooler uti-
Coolant level sensor lizes coolant to cool the intake air.
Coolant reservoir Although it utilizes coolant, the inter-
cooler has its independent cooling sys-
tem, not introducing the coolant from the
engine cooling system. It consists of the
from Turbocharger intercooler, electric water pump, sub-
Intercooler computer radiator, and intercooler computer.
The illustration on the left shows the 3S-
GTE engine produced from 1989-1999.
(1/1)

Sub-radiator

Electric water pump

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Precautions for Turbocharger
1.Precautions on handling
(1) The engine oil used for the engine equipped with the turbocharger is used for not only lubricating the engine but
for lubricating and cooling the turbocharger. As the engine oil is exposed to the heat of the turbocharger, its tem-
perature rises easily.
For this reason, the engine oil and engine oil filter maintenance should be carried out faithfully. Otherwise it
causes the turbocharger to damage.
If the recommended engine oil is not used, it causes the bearings of turbocharger to be damaged. Therefore, be
sure to use the recommended engine oil.
HINT:
Refer to the Owner's Manual or Maintenance Schedule as the replacement intervals of the engine oil and oil fil-
ter vary by the model or condition under which the vehicle is used.

(2) Since the bearings are not sufficiently lubricated just after starting a cold engine, racing or sudden acceleration
of the engine causes damage to the bearings.
(3) After the engine is placed under heavy loads, such as after high-speed driving or long distance driving, allow the
vehicle to idle for a few minutes before shutting it off.
NOTICE:
The turbocharger temperature does not rise too high while driving as the turbocharger is cooled by the oil and
coolant. When the engine is stopped immediately after high-speed driving, etc., circulation of the oil and coolant
stop. This causes the turbocharger to remain uncooled, leading to damage such as sticking. Thus, it is neces-
sary to idle and cool the turbocharger.

Driving condition Idling time

Normal city driving Not necessary
High speed driving About 80 km/h (50 mph)
-About 20 seconds
About 100 km/h (63 mph)
-About 1 minute
Steep mountain slopes About 2 minutes
or continue driving
above 100 km/h (63 mph)
(1/3)

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 2. Precautions on maintenance
(1)
(1) Do not start the engine with the air cleaner or air
cleaner case removed.
Otherwise it will allow foreign particles to enter caus-
ing damage to the compressor wheels and turbine.
(2) In the case that the turbocharger malfunctions and
must be replace, first check the following items for the
cause of the problem and remedy as necessary.
• Engine oil level and quality
• Conditions under which the turbocharger was used
• Oil lines leading to the turbocharger
(3) When removing the turbocharger, plug the intake and
exhaust ports and oil inlet to prevent dirt or other for-
(4)
eign materials from entering the system.
(4) When removing and reinstalling the turbocharger, do
not drop it, bang it against anything, or grasp it by eas-
ily deformed parts, such as the actuator or rod.
(2/3)

(5) When replacing the turbocharger, check for the accu-

(5)
mulation of carbon sludge in the oil pipes, and if nec-
essary, clean out or replace the oil pipes, too.
(6) When replacing the turbocharger, put the oil into the
turbocharger oil inlet and turn the compressor wheel
by hand to spread oil on the bearings.
(7) When overhauling or replacing the engine, cut the fuel
supply after reassembly and crank the engine for 30
seconds to distribute oil throughout the engine. Then
idle the engine for 60 seconds.
(3/3)

(6)

- 13 -
Exercise

These are the pre-course study materials for the Frequent Service Job Course. The objective of this course
is to learn the work procedure and points of frequent service jobs. In the pre-course study, you will study the
basic knowledge needed for repair work, and the basic mechanism and operation of automobiles. After you
finish studying all of the chapters, please take the Examination.

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Answers Answers
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- 14 -
Question- 1
Mark each of the following statements True or False.

No. Question True or False Correct Answers

The turbocharger and supercharger are devices that force air into
1 the cylinders at a pressure that is higher than the atmospheric pres- True False
sure to increase engine output.

2 A turbocharger is driven by the belt to increase engine output. True False

One of the functions of an intercooler is to cool the intake air that

3 True False
has reached a high temperature by compression.

Question- 2
The following statements pertain to turbocharger control. Select the statement that is True.

1. The waste gate valve is slightly open when the boost pressure is within the specified pressure.

2. The waste gate valve is open when the boost pressure is above the specified pressure.

3. The intake air is bypassed when the waste gate valve opens, and this prevents the boost pressure from
increasing above the predetermined pressure.

4. The actuator opens the waste gate valve when its diaphragm is pushed by the exhaust gas.

Question- 3
The following statements pertain to the precautions for handling a turbocharger. Select the statement that is False.

1. Make sure to use the recommended type of engine oil.

2. Race the engine immediately after a cold engine starting in order to thoroughly lubricate the bearings
before driving the vehicle.

3. When stopping the engine after it has been driving at high load, idle the engine for a few minutes.

4. To prevent damage, do not operate the engine with its air cleaner removed.

- 15 -
Question- 4
The components of a turbocharger are illustrated below. From the following word group, select the words that corre-
spond to the numbers in the illustration.

3
2

a) Compressor wheel b) Turbine wheel c) Actuator d) Waste gate valve e) Variable nozzle vane
f) Full-floating bearings

Answer: 1. 2. 3. 4. 5.

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