I i1)YOTA

~E TRAINING

Vol. 2,

TUrbocharger & Supercharger

Step 3
: TEAM Pub.No. nM302EN
TABLE OF CONTENTS
Page
DESCRIPTION
Necessity of Turbocharger and Supercha rger ... ,
Feat ures of Turbocha rger and S upercha rger . ... 2
How to Increase Fuel Inj ect ion Volume 3
Toyota's Turbochargers and Supercharger 4

TURBOCHARG ER
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5
Turbocha rger . . . . . . . . . . . . 6
Lubr icat ion and Cooling Syst ems . . . . . • . . . • . . . . . . . . . 8
Was te Gate Valve and Act uator . . . . . . . • . . • . . . . . . . . . . 9
Inte rcooler .. . ... .. . . .. .. .. • .. . • . .. . . . ... . . . . . .. • . 13
A ir By-pass Valve ... .. . . ... .. .... . .... ..•... . . . .. . 16
BOOS1 Pre ssu re Indicator . ........ . .. ....... ... . . .. • 17
Precaut ions , .... ......... .......• 2 1

! i INSPECTIO N OF TUR BOCH A RGER

On-vehicle Inspect ion of Turboch arger ..... • .. . . . ... 24
Off -vehicle Inspect ion of Turbocharger 26

SUP ERCHARGER
Description .. . .. . . .. .. . .. . • .. . .. .. .. . . .. . . . . . . . . . . 27
Supercharger . . . •............. . . .. .. . .... ... ..... 28
A ir By-pass Valve . ..... . . .. . .. .. . . . . . . ... . . . . . . • . . 32
Air Control Valve ........ ... . •.. . .. _ 38

!iI NSPECTION OF SUPE RC HA RGE R

On-vehicle Inspecti on of Supercharger 39
Inspect ion of A BV and VSV 41
Inspect ion of ACV .. .. . . . . ... . ... . .. . . ....... •.. , , . 4 1
Replacement of Clutch Stator , , ."" _ 42
 DESCRIPTION - Necessity of Turbocharger and Supercharger

DESCRIPTION
NECESSITY OF TURBOCHARGER AND SUPERCHARGER
tn designing an engi ne. th e balan ce between
hi ghe r power on th e one hand and lower weight
and sm aller size on the other mu st be taken into
considerati on.
One w ay to make the engine able to meet both
requ irements is to equ ip it w ith a tu rbocharger or
supercharger. This allows a greater volume and
weight of co mpressed air to be bu rnt w ith a
greate r amount of fue l. resulting in a great er
powe r output for an engine of a given size.

Ordinary eng ine Turbocharged engine or supercha rged engi ne

COMPARISO N OF WEIGHT/POWER RATIOS

WAYS TO INCR EASE POWER

In most intern al com bust ion engines. the amount in a given peri od of t ime . Due to th is fact. there
of pow er that can be obtain ed fr om an engine of a are several diff erent met hods t hat can be used to
give n displacem ent is deter mined by the amo unt increase engine output . Thr ee typical ways are
of air that is dra wn into the combust ion chambe r shown below :

This is t he most obvio us way. but because

I INCREAS ING ENGINE DISPLACEM ENT I ~ the weight of the engi ne may also increa se if
this is don e. there is not mu ch improvement
in terms of the weig ht-to-power rat io.

Conventiona l engines are limited to about

I INCREA SING MAXIMUM ENGINE SPEED I~ 6.000 rpm due to the increased frict ion loss.
noise and vib rati on. and decreased intake
effi ciency tha t occur at hig h speeds.

Using th is method, the amount of air neces-

CHARGING CYLINDERS WITH DENSER
AIR (USE OF TURBOCHA RGER OR SUPER-
CHARGER)
sarv for combustion of the ext ra fuel ca n be
~ grea t ly i nc reased, resu lting in in creased
power outpu t.
 DESCR IPTION - Features of Turbocharger and Supercharger

FEATURES OF TU RBOCHARGER AND SUPERCHARGER

The turbocharger and the supercharger are both a
kind of air pump, wh ich force the intake air into
the cyl inders to inc rease its density. The pressure
t Turboc harged engine
J
of the intake air thus supp lied to the cyli nders by
the tu rbocha rger or the supercharger becomes
greater than atm ospheric press ure and its density r---- ---T------
i ncreases beca use t he cy l inders are closed II Superch arged engine
vessels. I
These features are summarized in t he foll owi ng I

table:
Engine speed-i-c-e-

TURBOCHA RGER SUPE RCHARGER

Turbine (turbine and compressor
Type of cha rge r w hee ls)
Driv ing m ethod Exhaust gas pr essure
Smal l because tu rbocharger is
Power loss
driven by exhaust gas pressure
Sm all in low -speed ranges and
Charg ing effect large in hig h-speed ranges (The
causes is a small amount of exhaust
gases during low eng ine rpm .)
The res po nse duri ng low eng ine
Response rpm is not as good as tha t of t he
supe rcharger.
* The Roots type supercha rg er IS th e m ost com m on typ e i n use at prese nt.
Mechanica l (Roots type super-
charger* using one pai r of cocoon -
shaped rotors)
Engi ne crankshaft drive
l arge because supercharger is
dr iven by crankshaft.
Charg in g is possible in all speed
ran ges.
Go od respo nse is ob tai ned becau se
supercha rge r is directly driven by
crankshaft .

I
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I

TURBOCHARGED ENGINE (2L -T) SUPERCHARGED ENGINE (4A -G2E)

OHPOI
2
 DESCRIPTION - How to Increase Fuel Inject ion Volume

REFERENCE
• CHARGIN G EFFICIENCY
In an ordinary engine. th e charging eff iciency of
th e intake air into t he cyli nders is only 65 to 85%
due to t he res ista nce of th e intake syste m and
th e ex h aus t gas rem aining i n t he exh aus t
system. With a turboch arged or supercharged
engine, this eff iciency can be mo re than 100%.

M ass of air act ually taken in

Cha rging efficiency (%);;; --==,--;,.,.,.::::=c=:--;:::....::.:::.:;:-~....::.:::.:;:-c..:;-'---,7"----:~- X 100
M ass of air in cyli nde r und er standa rd conditions"

" Standard conditions: Standard at mosphe re pressure at 20°C (68° F)

• COM PRESSIO N RATIO

A ga so line eng i ne has a tende ncy of kn ockin g w hen the in take ai r vol ume is in crea sed .
Therefore, in o rde r to prevent fro m knocking t he compression ratio of a t urboc harged or
supe rcha rge d engine is m ade slig htly low er t han that of an ordina ry eng ine.

HOW TO INCREASE FUEL INJ ECTION VO LUM E

Even w ith a turbocharged or supercharged engine, a fuel v olume suited to the intake air vo lum e is
required. Accor dingly, the am ount of fue l consumptio n increases in proportion to th e increase of pow er.

• W ith a diesel engine, a tu rboch arger boost
compensator is fi tted to th e governor of t he fu el
inj ecti on pump to regu late t he fuel inj ection
volu me in accordance w ith th e boost pressure.
(See Step 3 Trainin g Ma nua l, Vo l. 3, " Diesel
Inj ect ion Pump" , for details.)
• W ith an EFt gasoline engine, th e air flow met er
detec ts th e int ake air volume, and th e Engin e
ECU dete rmines th e f uel inj ect ion volume (the
length of time th at th e inj ectors operate during
each injection cycle), so a specia l device is not
necessary.

Turbine wheel Compressor w heel

eXhaust:~~r~t~~~C:3
pipe
To
From air
cleaner
Boost compens ator

Was te gate
valve

Act uator Boost press ure

(compressed air )

Exhaust gas
-
Diesel inj ection pum p

TURBOCHARGED DIESEl ENGINE OHP02

3
 DESCRIPTION - Toyota's Turbochargers and Supercharger

TOYOTA'S TURBOCHARGERS AND SUPERCHARGER

Toyota used a turbocharger for the first time in equipped w ith a turbocharger or a supercharger
1980, and the supercharger in 1985. Engines are listed below .

ENGINES WITH TURBOCHARGER

Engine type Inter cooler

Air-cooled Wa ter-cooled

Gasoli ne R series 22R-TE - -

engine
5 series 3S-GTE 0 0
M series 7M -GTE 0 -
JZ series 2JZ -GTE 0 -

Diesel C series 2C-T - -

engine
L series 2L-T - -
KZ series 1KZ-T - -
8 series 13B-T.1 4B-T -. . . . . .
... ---- - - - _. . . . . . . _-- - . . . . .
-
-------------
15B-FT 0 -
H series 12H-T - -
HZ series l HZ-T - -
HD series lHD-T. 1HD-FT - -
ENG IN ES WITH SUPERCHARGER

Engine type Inter cooler

Air-cooled Water-cooled

Gasoline A series 4A-GZE 0 -

engine
T2 series 2TZ-FZE 0 -

4
 TURBOCHARGER - Description

TURBOCHARGER
DESCRI PTION
The turboc ha rger is basicall y an air pump that is
des igned to ut ilize some of the fuel's energy that
would otherwise be w asted in the form of exhaust
gases.
These exhaust gases drive the tu rbine w hee l.
which is coupled to the com presso r wheel by
means of a shaft . This compressor wheel is drive n
at high speeds, forcing mo re air into the'cvlinders.
Since t urbochargers use the wasted energy of the
exhaust gases. the power output of the engi ne
can be increased with less power loss.
Turbocharger are used in bot h gasoline engines
and diesel engi nes . Th eir principle of operation is
the same .
The tu rboc harger is provided with a waste gate
valve to control the boost pressure on the inta ke
air.
So m e turbocharged eng in es are also equipped
wit h an intercoole r to lower the in take ai r
temp erature. This prev ents engine knocking
and improves air i ntake eff icie ncy .

NOTICE- - - - - - - - - - - - - - - - - - - - - - - -- - - - - -r-,

A s the tu rbocha rger become s extre me ly hot due to the exhaust gases. proper preca utions fo r
han dl ing th e veh icle and cha nging t he eng ine oil mu st be observed. Refer to pages 21 and 22 fo r
t hese precau tions .

Ai r cleaner

..
Turboch arger Ai r flow mete r fif'=-::r"",

C>

Turbi ne wheel
Compressor wheel

Air intake chamber

Actuator
t Intercooler

III
Wa ste gate va lve

- ~ Exhaust gas
¢:J Intake air

TURBOCHA RGER SYSTEM OHP03

(7M -GTE o n Supra)

5
 TURBOCHARGER - Turbocharger

TURBOCHARGER
The turboc harger co nsists of t he turbi ne hou sing, w heel , compressor wheel, full floating bearing s.
compresso r housing, cente r housing, turb in e waste gate valve. actuator, etc.

Turbine w heel Full -floatin g bearings

Waste gate valve \ I

To in take manifold

r::!:l

From air cleaner

Compressor wheel

From exhaust
manifold Actua tor

,--- - - - - - - - - - - - - - - -
I
- - - - ,I
These com ponent parts are supplied as one unit

I I
I
I ~ Center housing II
I
I
I I
I
I I
I I
I ~
I
I
L- Waste gate va_lve

Actuator

CONSTRUCTION OF TURBOC HARGER 12l-TI OHP04

6
 TURBOCHARGER - Turbocharger

1 . TURBINE A ND COMPRESSOR 3. FULL-flOATIN G BEARINGS

WH EELS
The turbine wheel and the compresso r wheel are
mounted on the same shaft . Exhau st gas flow s
from the exha ust manifold to the turbine wheel,
an d the pressure of the exh aust gas tu rns the
turbine w hee l.
When the turbine w hee l turns, th e compresso r
whee l also tu rns, forcing the intake air in to the
cylin ders .
Sin ce the t urbi ne wheel is exposed directl y to the
exha ust gases. it becomes extremely hot; and
since it rotates at high speeds. and must be heat-
resistant an d durable. it is made of an ultra-heat-
resista nt alloy or ce ramic.
Since the tur bine and comp ressor w hee ls t urn at
speeds of up to , 00.000 rpm, full-floating bearing s
are used to ensu re the absorpt ion of vibrations
from the shaft and lubricati on of the shaft and
bearings .
These bearings are lubric ated by the engine oil
and rotate fr eely between the sha ft and the
hous ing to prevent seizing du ring hiqh-speed
operation.
Engin e oil is prevented from leakin g by two ring
seals or by a mechan ical seal and a rin g seal fitted
to the shaft.
4 . WASTE GATE VALVE AND A CTUATOR

The waste gate valve is bui lt into the tur bine

2 . CENTER HOUSING
The center hous ing supports the turbine and
com presso r wheels via the shaft .
In side the housing, engi ne oi l is ci rculated
through channel s that are pro vi ded
lubricat ing t he shaft and t he bea ring.
A lso, engi ne coo lant is ci rcu lated t hrough
coolant channels th at are built into th e ho usin g
in orde r to prev ent the engine oil tem perature
fr om risin g.
housin g. Its. purpose is to reduce the boost
pressure when t hi s begins to rise too hi gh . W hen
this valves opens . part of the exhaust gas by-
passes the t urbine w heel and flow to the exhaust
for pipe.
The opening and closing of the waste gate valve is
controlled by the act uator.

Oil channel
Coolant channel
Compressor wheel

\o~
Turbine wheel

Ring seal
Mechanical seal
Full-floating bearings

CENTER HOUSING (2L·n

7
 TURB OCHARG ER - Lubrication and Cooling Syste ms

LUBRICATI O N A ND COOLING SYSTEMS

1. LUBR ICATION SYSTEM 2 . COO LING SYSTE M

In order to lubricate the f u ll -f loating beari ngs
inside the center housing, eng ine oil is supplied
fr om the oil in let pipe and circ ulated among t he
beari ngs.
Afte r lu br icat ing th e bearinq s. th is oil passes
thr ough t he oil out let pipe and ret urn s to the oil
pan.
Th e turbocharg er is coo led by eng ine coolant.
Engin e coolant is sent from the thermos tat hous -
ing and int roduced into the coolant chan ne l
(provided in th e cente r housing) via the coolant
in let pipe.
Afte r cooling the turbocharger, the coolant passes
t hrou gh the coolan t out let pipe and returns to the
w ater pump.

Coolant inlet pipe

From oil filter bracket Coolant channel

Coolant channel
From
thermostat
\'"'-,,~ h o u s i n g

• t
To oil pan From oil filter bracket

LUBRI CATION A ND COO LING SYSTEMS (2 L-T) OHP05

8
 TURBOCHARGER - Waste Gate Valve and Actu ator

WASTE GATE VALVE AND ACTUATOR

A t urbocha rger atta ins a h igh outp ut by boosti ng
the pr essure of th e air fed into the cylin ders, but if
th e boost pressure ri ses to o h igh, the exp losive
force created by comb ustion of t he air -fuel mixt ure
w ill beco me too great and t he engi ne w ill be
un able to w it hsta nd th e press ure . Therefore,
boost press ure is cont rolled by t he act uator and
waste gate valve.
With some gaso line engi nes, t he boost pr essu re
is also co ntrolled in accordance wi th the octa ne
rat ing of the fu el used (pre mi um or regul ar
gasoline).

1 . BOOST PRESSURE C O NTRO L

The boost pressu re of most engines is co ntro lled

by the actuator and waste gate va lve. Here, we
w ill explain the boost press ure cont ro l, using t he
2L·T eng ine as an example.

CD BOOST PRESSU RE BELOW 6 6 .9 kP.·

(0 .68 k9f/cm 2; 9.67 psi)

As long as the boost pr essure inside t he inta ke

man ifold is below 66 .9 kPa (0.68 kgf/cm 2; 9.67
psi) the actuator does not operate and the waste
gate valve rem ain s closed. A ll exha ust gas IS

the refo re routed into the tu rbi ne hou sing.

" This d epend s on m o dels

Turbine wheel Compressor wheel

., ,

Waste gate valve

•- • -
-----II--J~~~
(closed)
Actuator
,
"...;. '_"II' ~ To combustion
~ chamber
Exhaust gas
(from combustion

-
chamber)

OHP06

9
 TURBOCHARGER - W aste Gate Valve and Actuator

@ 800ST PR ESSURE REACHES 66.9 k Pa '

(0. 6 8 kgf/ cm ' ; 9 .67 psi)

As th e accelerator pedal is depressed (and th us as
the fu el inj ecti on volume incr eases), th e exhaust
gas pressure inc reases, thus in creasing the boost
pressure.
W hen the boost pressur e reaches 66.9 kPa (0 .68
kgf/cm 2; 9.67 psi) - that is, the int ercept point -
the waste gate valve is open ed by th e act uator
(due to t he co mbined for ces of th e exhaust gas
pressur e on th e w aste gate valve and the boost
pressure on the act uator diaphragm) and part of
the exhau st gas is di verted around th e tu rbine
w hee l. A s a resu lt, t he t urbine speed is kept
w ithi n the opt im al range to preve nt th e boost
pressure from rising excessively.
" This de pends on m odels

Turbine wheel Compressor wheel

OHP06
~ REFERENCE -
The relationship betw een the engine speed and
boost pressure .w hen th e accelerator pedal is
fully depressed is shown in th e graph at the W aste gate valv e opens
righ t. These characteris tics w ill vary depend ing t r
upon t he load that is placed upon the engine. "'-Intercept point

Engine speed -

10
 TURBOCHARGER - Waste Gate Valve and Act uator

2. CONTROL OF BOOST PRESSURE USING ENGINE ECU

The boost press ure is basically cont rolled by t he

actu ator and waste gate valve as menti oned
Premium gasoline
previou sly. In some gaso line eng ines, the boost (VSVon)
pressur e also is controlled in two patt ern s in
accordance w ith th e type of fu el used (prem ium
1
Regula r gasoline
or regular gasolin e). (VSV off l
Th is maximi zes engine performa nce and main -
tains engi ne durabili ty, as well as suppress ing
knocking under all eng ine runnin g con dit ions,
including during w arm -up, irrespect ive of th e
gasolin e octa ne rati ng.
The following descript ion is based on the 3S -GTE
Engine speed -
engi ne (ST185).

Pressure at the inlet side of the compressor Turbine wheel Compressor wheel
ho using is introduced into the actua tor via t he
VSV (Vacuum Switch ing Valve) w hich is controlled
by the Engine ECU.
The Engine ECU turns the VSV on or off depending
on w het her premium or regular gasoli ne is bein g
used (as determ ined by the knock sensor signal)
and engi ne condit ions .
The VSV stays off w he n regula r gasoline is used.
When pre m ium gasolin e is used, t he VSV is
tu rned on .
-
'----i~EC
=U~ Various signals
W hen th e VSV goes on, the press ure applied to OHP08
the act uator escapes to the inl et side of the
Turbine wheel Compressor wheel
comp ressor ho using . As a result, t his pressure
{Pa] becom es low er th an the boost pressure (PS).
The .difference between th e press ures (Pa) and
(PS) is about 19.6 kPa (0.2 kgf/cm 2; 2.8 psi).

Fo r th is reason, w he n t he VSV is t urn ed on, the

-
boost pressure becomes higher t ha n th e t ime Actuator Waste
VSVoff
w he n the VSV is tu rned off, thus increasi ng the '-':;;'''f''tgate
valve
engin e pow er.
Pressure Pb
~~~
ECU Various signals
OHP08

11
 TURBOCHARGER - W aste Gate Valve and Ac tua tor

REFERENCE ----------------------~----r->,
TWO,WAY TW IN TURBO ON 2JZ-GTE ENGINE
An engine equ ipped with a sing le tu rbocharge r
is hard to provide a good engine response from
low speed th rou gh high speed and to generate
high pow er at the same time.
Th e 2J Z-GTE engine is equipped w ith two
small t urboc h argers. Ow in g to t hi s, only one of
t he tu rboch argers is activated during low
speed or low load conditio ns to provide a good
response and bo th turbocha rge rs are activated
d uring hi gh speed or high load conditions to
generate high powe r.
The Engin e ECU mi nutely con trols t1W opera -
tion of the waste gate va lve and th e exhaust by -
pass valv e by a lin ear-typ e VSV. and th e ex-
hau st co nt rol valve and t he intake air co ntrol
valve by an ON-OFF type VSV.

• Intake air control valve permits or stops t he f low o f intake air th rough t he NO. 2 tu rbocharger.
• Exh aust gas co nt ro l valve permits or sto ps t he fl ow o f exha ust gas through the No.2 t urbocharger.
• Waste gate valve co nt ro ls t he boost press ure of t he ent ire syste m by bypassing a po rt io n of th e ex-
hau st gas flowing t hro ugh th e No . 1 t urbocharger durin g a two-turbocharger bo ost operatio n.
• Exh aust byp ass valve co ntrols the boost press ure of the entire syste m by bypass in g the exha ust
gas f rom t he No .2 turbocharger d uring a si ng le-tu rbocharger boost ope ration (w hen only th e No .
1 turbocharger is boosting). At the same ti me. this bypass allows the tu rbine whee l of t he No .2
t ur bocharger t o start spinn ing ahead of t he starting of t he NO.2 turbocharger operation.

Exhaust gas control valve

Ai r cleaner
-
._. --
NO.2 tu rbocharg er
. -'

.
4~:: : lolr./LEXhaust bypa s s va lve

..
,
'-,..','-," '.,..','-,,.'.-r;,.. ' ,-, Intake air control valve
' .' ' .' ' .' '.' '-' ' -'

Waste gate
valve

'.
Intercooler
IL

12
 TURBOCHARGER - Intercooler

INTERCOOLER (so m e models only)

As intake air is compressed by the turbocharger.
its temperatu re increas es. Cooling the intake air
raises the air density (improving intake eff iciency).
th us ensuring high power. At th e same time, by
towe ring the temperature of the air fuel mixture.
knocking is suppressed. giving im pr oved dr iv abl -
lity and f uel economy.
Intercool ers are used to cool t he t urboch arg ed air
and are eithe r of th e air-coo led type or the w ater-
cooled type.
The air-coo led ty pe intercooler utilizes the vehicle
wi nd stream or an engine cooling fan .
This syste m is simple. as shown below. The
inte rcooler may be insta lled at var ious locations
depending on the veh icle mod el.

Air
cleane r

.. Turbocharger

Compressor wheel
Ai r flow
mete r
C>

Air intake chamber

Actuator
t Int ercooler

Waste gate valve

TURBOCHARGER WITH INTER CO OL ER

17M-GTE on Supra)
Intercooler

A ir cleaner Tur bocharger

~
~\ ""~

: I \ ~
~Y~lj /
Inte rcooler

AIR -CO OLED TYPE INTERCOOLER A IR-COOLED TY PE IN TER COOLER OHPQ9

(3S ·GTE on 4WD Celica [ST 185)) 17M -GTE on Supra)

13
 TURBOCHARGER - Intercooler

REFERENCE

W ATER-COOLED TYPE INTERCOOLER

The w ater-cooled type intercoo ler w as used on ly NonCE CONCERNING INTERCOOLER
for t he 3S -GTE eng ine in th e 4WD Celica COOLANT:
(ST 165 a nd ST20 5).
• Use a nt if reeze coola nt f or t he int ercooler
(a 50 t o 70% solut io n on ly).
1 . DESCRIPTION
• Check t he intercoo ler coo la nt level frequ en t ly.
Th e pu rpose of t he water-cooled ty pe inter cooler Lack of coo lant m ay impair t urbocharger per -
is the same as that of the air-cooled typ e. for mance .
How ever. t he cooling syste m of th e wate r- • Do not reuse coo lant in the intercooler w h ic h
cooled type intercooler is ind ependent from the has already bee n used fo r t he engine .
eng ine cooling syste m .
The coolant passing through th e intercooler is 2. INTERCOO LER
force-fed to the sub- radiator by an electric w ater
Th e intercooler is locat ed above t he cy linde r
pum p. (Th is sub-radiato r is located in front of the
he ad . The insi de is divided into ai r and coo lan t
ma in radiato r.) Afte r being cooled by the ram air ,
passages, so t ha t th e intake air enteri ng t he
the coo lant is ret urned to the intercooler.
in tercooler is coo led as it f low s t hro ugh t he ai r
passages.
To air inta ke chambe r
.,-.;:; _.?:J Inter cooler To throttle body
~~~ Coolant level Coolant level sensor
~~X, se nsor ""'''''_ I
- - --::::::::....~,
Coolant
From z;J~~ reservoir

!\0t;b",:urboCharge rl
Intake air To electric
w ater pump
--- ~ From tu rbocharger From
sub- radiator
~1.
A coolant level sensor is in st all ed in the in ter -
Sub-radiator / \h '0:::!-!
Electric w ater pump coo le r. Thi s sensor is nor m a lly on. Whe n t he
coo la nt leve l drops an d t he f loat fa lls be low a
pr edet ermined leve l, t he se nso r is t ur ned off by
Turbocharger Intercooler a m agnet in side th e f loat. Th is wa rns the inter-
Ai r intake
chamber coo le r co m p u te r th at th e coo la nt level has
Air cleaner ~~~
dropped .
I
O-r ing
Air f low m eter·r,2~:;;;;;:;;;;;;;:;:!,,;~dO
Ram air
Sub-radiator Electric wate r
pump

14
 TURBOCHARGER - Intercooler

3. ElECTR IC WATER PUMP

W IN Fuse
•"
The elect ric wa ter pump consis ts of t he coo lant
pump and t he pu mp dri ve moto r. As th e p ump Engi ne
ECU *
-
E
,"
c,
w aterl lg nition
M pump switch
dri ve motor rotate s, the impeller rotates to fo rce- 0 drive
feed t he coola nt from the intercooler to the
IDl Q
motor
"
sub-radia tor. "00 -7"""

I
Pump drive motor Coolant pump
I I
Cool ant
level sensor
~

-"
c
.-
,,

Impeller
-
W IN: Intercooler coolant level signal
From IDL: Throttle position signal

~~~~~=~ ~rcooler »On the ST205, the intercooler computer

is combined into the Engine ECU.

MOTOR ·ON CONDITIONS

Rubber washer Water inlet • The ignit ion switc h is ON w ith t he throttle
Mechanical seal valve open (IDL poi nt of the thr ottl e positi on
sensor off).
• The ign ition switch is ON for a pr edet er min ed
Water outlet Impeller
length of time after the throttle valve has been
To sub- closed (IDL point on).
radiator I

I
u~
. Water
inlet
4 . INTERCOOLER COMPUTER
The int ercooler comp ute r co ntrols t he w ater
pum p drive motor acco rding to the signals from
the throttl e positio n sensor (via the Engine ECU),
and from the inte rcooler coo lant level sensor.
The intercooler com puter has a self -diagnost ic
funct ion for detect ing malfuncti ons; thi s f unction
is sim ilar to tha t of th e Eng ine ECU.
Intercooler computer
_.::c::;:~~_-:--_:~:~::};;~:?!f:
MOTOR ·OFF CONDITIONS
• The ign ition switch is at LOCK or ACC.
• The ign itio n switch is ON for a pr edeterm ined
length of time aft er t he th rottle valve has been
closed (IDL point on), or fr om ign it ion switch -
on to the mo ment that the IDL point goes off .
• The inte rcoo ler coolant is below a predeter-
mined level.
• The motor seizes up or an open ci rcui t occur s
dur ing moto r operatio n.
SElF·DIAGNOSTIC FUNCTI ON
If the int ercool er coolan t level drop s below a
predete rm ined level. the w ater pump drive motor
seizes up, or an open circu it occurs duri ng motor
operation, the intercoo ler co mpute r stops th e

/o-'~~j):-:J_~;,;CC}7
supply of cu rrent to the motor. The intercooler
computer th en sends a signal to t he Eng ine

J~rLe~--'l ECU, w h ich activ ates th e CHECK ENGINE lamp

to warn the drive r of t he abnormality.

15
 TURBOCHARG ER - Air By-pass Valve

AIR BY-PASS VALVE (ABV) (some models only)

Even whe n the eng ine decelerates and yo u wo uld
expect t he tu rbocharger to stop operating, turbo-
cha rging act ua lly cont inues br ief ly due to the
inert ia of th e tu rboch arger turbine. For th is reaso n,
th e pressure in t he air passage betw een t he
tu rbocharger and the throttle valve remains hig h .
T hi s t en den c y becomes more pro n ou n c ed i n
eng ines in wh ich the distance betw een th e t urbo-
cha rge r and th e throttle valve is gr eater due to the
intercooler location , resulting in t he product ion of
air shock noise. Acc ord ingly, in such engines, an
air by-pass valve is provid ed to release thi s
pressure in order to red uce th is noise,
The explanat ion below is based on the air by-pass
valve used in 3S-G TE engines for the MR2
(SW20).

i . CONSTRUCTION
Chamber A Vacuum hose

/ ~===
The air by-pass valve is opened and closed by th e
vacuum applied via t he vacuum hose f rom t he

..
intake air cha mber. The vac uum hose is divided,
~To intake
one branch leading to chamber A and th e other air chamber
lead in g to cham be r B. Th e hose leadi ng to
VTV
cha mber B has a VTV (Vacuum Transmi tt ing
Va lve) installed in it to delay applicat ion of the Air by-pass valve
vacuum.
OHP 10
2 . O PERATION

When the engi ne decelerates, a strong vacuum is
applied to chambe r A by the vacuum hose, but the
vac uum is not applied ri ght away to cham ber B
because of the VTV. Acco rding ly, t he diaphragm
is pu lled tow ard cha mber A where t he vac uum is
strong, thus pulling open the air by-pass valve.
As a resu lt. t he comp ressed air returns through
the air by-pass valve to th e in let side of the
compressor w hee l.
The air press ure betw een the turbocharger and
the throttle valve is thus reduced, result ing in
reduced air shock noise.

Thrott le valve
Intercooler

- r @ II U1III1I1M
IlIIl\Il1\1\I0UIn
rvUVUWIIII!I/1

t Air by-pass
valve
Chambe r A

Compressor
wheel
-l
- -
VTV
D Chambe,s
£1~~"'.='lntake air
A ir flow meter
Turbocharge r
AIR BY-PASS VALVE SYSTEM OHP 10

16
 TURBOCHARGER - Boost Pressure Indicator

BOOST PRESSURE INDICATOR (some models only)

Turbochargin g indicator lights or a tu rbocharger charger is wo rking norma lly.
meter is provided to in dicate w hether the t urbo-

1 . TURBOCHARGING IN D ICATOR LIG HTS

These lights are green and am ber LEOs (l ight - INDICATOR /WAR NIN G LIGHT OPERAT ION
emitting di odes) and are used to te ll the dr iver Turbocharging Over-charging
Lights
indicator warning
w heth er t urbocharging is proceeding norm ally or Condit ion
(green) (amber)
not. The tu rboch arging indicator lights for the Starter switch on (engine stopped) ON ON
Land Cruiser (W70 series) are explained here.
Engine idli ng OFF OFF
\ \ \ ~O '8 '1 Boost pressure over 13.7 kPa
ON OFF
(0.14 kgflcm' ; 2.0 psil
,'\ 3 t'" Boost pressure over 82.4 kPa
:::
...
2 ENGINE
>l OO O r / m ln
4 .-;.._ 10.84 kgf/ cm 2; 11.9 psi) OFF ON

~OJ} G) Starter Switch On (En gin e Not Running )

TURBO ©I'::;":L-~
.--":-«0))
Turbocharging ~ . _. --- '<:;::.'
/ Over-.charging Elect ric current flow s th rough th e cir cuits
indicator light ~ warn ing ligh t shown below and t urns on the green an d
(green) (amber)
amb er LEOs to allow LED failure check ing to
PRESSURE SWITCHES be carried out:

The boost pressur e is sensed by tw o pressure

ENG INE Combina ti on mete r
switches (a low -pressure switch and high -pres - fuse . .
sure switc h). The on / off operat ion of th ese Voltage .T Green-J: 'ALEDmbe~'~-
-I-
switches cont rolIs t he opera tion of the t ran sistors regu lator '
r-., LED · b: , ,
(Tr, and Tra). w hich in turn control th e sw itching ! ~
L J z,
I'@l~
- ,

of the indicator and wa rn ing lights. . T"

. ~ r. ,
Note that the only diffe rence in the const ruction I r? .
of the hiq h- and low -pressur e switches is in the L . .
"f- .
strength of t he spring.
- 1SWitch ~t"h'
W hen the boost pressure applied to th e diaphragm
exceeds a ce rta in level, the switch con tac ts open . 1 [1jLO
-L
W' e [
pre.ssure
.1,.
pressu re
SWitch
__

Spring Diaph ragm OHP 11

REFE RENCE
The voltage at points @ and @ is zero, so Tr 1
Boost and Trz are off.
pressure

Fixed point
Moving point
PRESSURE SWITCH

17
 TURBOCHARGER - Boost Pressure Indi cator

(2) Engine Idling @ Boost Pressure Above 8 2 .4 kPa

(0 .84 kg f / cm 2; 11 .9 psi)
W he n t he eng ine is started, th e voltage applied to
terminal L of the voltage regulat or becomes the If t he boost pressur e ri ses eve n high er and
same as battery voltage . Ther efore, t here is no reach es 82.4 kPa (0 .84 kgflcm 2; 11. 9 psi), th e
difference in t he pote ntial across t he ends of each con tacts of t he high-pressure switch open and
LED, so both LEOs t urn off. th e potenti al at point @ rises. This causes curre nt
to f low throu gh Ze ne r diode Z2. t urn i ng on
ENGINE transistor Tr2' As a result, th e ambe r LED lights
fuse
up. wa rn ing the driver th at t he turboch arger is
Voltage
regulator ' operating abnor mally.
r- ',
I
rK-r----1f-=- - "I"--t--== - '1 A t th is tim e, the contact s of th e low -pressure
a, switch rem ain open. How ever, si nce Tr2 is on (the
l" j ,
voltage at point © is alm ost zero). the voltage at
I , point @ is almost zero, and Tr 1 turns off . There-
T L_+ _-----<>-High-~ fore. th e green LED turns off-

~
LOW.
~

1 ~
pressure
sw itch
pressure
switch ENGINE
fuse
Voltage
Combination meter
---- ---ll
OHP 11
regulator
~ .~
I
Green
LED
~-t--,,,.---1 L..
Amber,
LED,
l©
'- I
~ I

(3-) Bo ost Pres sure Over 13.7 kPa

(0 ,14 kgflcm 2; 2 .0 psi)
. .J
, L ,. ~ I i
When the boost pressur e ri ses above 13 .7 kPa
(0.14 kgflcm 2; 2.0 psi) (i.e .. slightly higher th an
1_ _ --<)- l
atmospher ic pressur e) th e contacts of th e low -
pressure switch open and the potential at point ®
rises. The curren t th erefore passes throu gh Zener
diode Z, and turns on transistor Tr.. OHP 12
Thi s causes t he green LED to light up. indicating
that the turbocharger is operating. REFEREN CE
The pressure at w hich the high-pressure switch
ENGINE opens depend s on the engine. Generally. th is
fuse
press ure is slightly hi gher t han t he maximum
Voltage boost press ure . Therefore, th e amb er LED does
regulator Green,
r-', LED -
not l ight up as long as the waste gate valve and
th e act uator are fun cti oning correctly.
.J

-
1
OHP 12

18
 TURBOCHARGER - Boost Pressure Indicator

2 . TURBOCHARGER METER

The t urbocharger meter inform s th e driver of the TURBOCHARGING PRESSURE SENSOR

tu rbocharging pressure detected by th e turbo -
chargi ng pressure sensor .
The turboch arger meter for the 4WD Celica
(ST18 5j is expla ined here.
TURBOCHARGER METER
The turbocha rger meter incorporates a co il, and a
magnetic rotor which moves together w it h the
needle shaft.
When the size of t he current f lowing through this
coil changes, the strength of the mag netic field
cha nges acco rdingly, and the m agnetic ro tor (and
th us the needle) tu rns .
This cu rrent is controlled by the tu rbocha rger
meter dri ve ci rcu it (an IC), wh ich is incorpor ated
into the comb ination meter.
The basic constructio n of t his sensor is th e
same as t hat of t he m an if o ld pressur e
(vacuum) sen sor used on EFl engi ne.
A silico n ch ip in a vacuu m chamber is incorporated
into the sensor un it. One side of this chip is
exposed to in take ma ni fol d press ure and the
other side to the intern al vacuum ch amber.
A cha nge in the intake manifold press ure causes
the sha pe of th e si lico n ch ip to cha nge, and th e
resistance of the chip fluctuates in accordance
with the degree of its deforma tio n. This fluctuation
in the resistance is converted to a voltage signal
by the IC built into the sensor, and is then sent to
th e t urboch arger meter drive circ uit as a turbo-
charging press ure signal.
Silicon ch ip

Norma l range ~

Vacuum chamber

Filter

Connector
t
Intake manifold pressure

TURBOCHA RGER METER TURBOCHARGI NG PRESSURE SENSOR

OHP 13

19
 TURBOCHARGER - Boost Pressu re Indicator

OPERATION

A constant 5 volts (the power supp ly) is supp lied

from the Vc te rmi na l of t he Engine ECU to the IC (VI
in t he tu rbochargin g pressure sensor. 5
A voltage (the turb ocharging pressur e signal) is 4
sent from t he turboch arging pressure sensor to •
~
s
the tu rbocha rger meter drive circuit in the combi- 3
nati on meter . "5
>

"-
5 2
The dri ve circuit turns t he transistor on and off in
0
accordance w ith this voltage sig nal to exec ute 1
duty cont rol.
Changes in t he transistor duty causes changes in 0 13 .3 1000 200.0 (kPa)
the size of the current flow ing to the coil of the 100 750 1500 {mmHg)
3.9 29 .5 59 .1 {in.Hg)
turbocha rger meter, and ca uses t he stre ngth of Intake man ifold pressure
the magnet ic f ield to change.
As a resul t, the magnet ic rotor is turned and the CHA RAC TERISTICS OF TURB OCHAR GING
PRESS URE SENS OR
need le indicates the t urboc harging press ure .
OHP 13

Combination meter
Ignit ion GAUGE Engine ECU
Turbocharging
sw itch fu se TurbOCh a rge~ meter pressure sensor
Vc
Coil
•
5V I
0- .
- PIM
Ie
Turbocharger
met er dr ive
~
"
circuit Tr
.I .---=>
', J
,,
~

.r,
7"" "-
r
Silicon chip - From intake manifold
-

TURBOCHAR GER METER CIRCUIT OHP13

20
 TURBOCHARGER - Precaut ions

PRECA UTIO NS
The turbocharger is a prec ision -built part , but b. Be sure to use the follow ing types of eng ine
since its design is very simple, it is also very oil for turbocharged engines :
durable if a few simple preca ut ions conce rn ing its
use and care are observed. DIESEL ENGINE
The tu rbocharger operates under extreme ly severe
A PI gr ade: CD or bett er
co nd it io ns : t he t urbine whee l is exposed t o
exhaust gases w hose temperatu res reach as high Recommended viscosity (SAEI:
as 90QoC (1,652 OF) whe n the engine is run ning
20W· 50
at maximum load, and t he rotati ng assembly
15W-40
rotates at speeds of up to 100,000 rpm. Therefore,
10W·30
th at wh ich has t he greatest effe ct upon the
performa nce and durability of the turboch arger is
th e lubrication of t he bear ings t hat support t he · C- 29 18
SW·30

74
1 1I I I
16 27 38
' F - 20 0 20 40 60 80 100
t urbin e and comp ressor w heels . TE MPERATURERANGE ANTICIPATED BEFORE NEXT OILCH ANGE
Consequently, to prov ide lasti ng, tr ouble-fr ee
operat ion, the foll owing precauti ons mu st be GASOLINE ENGINE
observed: A PI SG or SH mu lti gr ade eng ine oil or ILSA C mul-
t igrade eng ine oil.
1 . PRECAUTIONS ON HANDLING
Recom men d ed visc osi t y (SAEI :
a. The engine oil becomes hot very quickly due
SAE 20 W -50
to its use in both coo ling and lu bri cat in g the
SAE 15 W -40
turbocharger, so it det eriorate s rapidly. For
th is reaso n, engi ne oi l and oil filter maint e- SAE 10 W -30

nance should be carried out faithfull y. SAE5W·30 · :j:tj:±j

The replacement intervals of the engine oil "C - 29 - 18 -7 4 16 27 38
and oil f ilt er are determ ined by the condit ions
' F -20 0 20 40 60 80 roo
TEMPERATURERANGE ANTICIPATED BEFORE NEXT OIL CHANGE
un der w hich t he vehicle is used and/or t he
countries/ regio ns in w hich the vehicle is to " Depends on engine mode ls
be sold.
Th er efor e please refe r to the appropriate
Owner's manual, Owner's manua l supplement,
Toyota service booklet , or Toy ot a w arra nty
book let fo r th e correct rep laceme nt intervals.

OHP 14

21
 TURBOCHARG ER - Precautions

c. Since the bearin gs are not suff iciently lubri - NOTE - -- - - -- -- - -""'
cated immediately after the engine is started, Wh y t he engi ne sho uld be all owed t o idle
racing or sudden acceleration of the engine before shut-off:
sho uld be avoided . Duri ng high -speed driving. the tu rbi ne wheel is
d. Do not stop the engine immediately w hen exposed to very hot exhaust gases, and its
pu lling a trailer or aft er high -speed or uphill temperatu re rises extreme ly high.
driv ing . Idle t he engine for 20 · 120 second s, Since the shaft linking the turbin e wheel to the
dep end ing on the seve r it y of the driv i ng comp resso r wheel is cooled by oil and coola nt,
condit ions. its temp eratu re does not ri se as high. Never-
theless, if the engi ne is stopped immediately
SUGGESTED IDLING TIM E BEFORE ENGINE af ter high -speed drivi ng, circulat ion of oil and
SHUT·OFF coolant w ill stop. and the temperature of the
DRIVING IDLING TIME sha ft w i ll sudde nly r ise du e t o th e h igh
Town or suburban driving below 80 temperature of t he tu rbin e wheel.
km/ h (50 mph) Not required
Therefore. letti nq the engi ne idle before shut-
High ·speed
Cru ising at 80 km/h
150 mph) IApprox. 20 sec. ting it off w ill allow th e shaft to cool off
driving Cruising at 100 km/ h gradually. (This is because the temperat ure of
Appr ox_1 min.
(63 mph)
t he exha ust gas is low er (300 to 400° C; 573 to
Driving over mounta inous roads. racing.
driving over 100 km/h (63 mph) conn-
(J( Approx_2 min . 752° F) duri ng idli ng.)
nuously.

22
 TURBOCHARGER - Precaut ions

2 . PRECAUTIONS ON MAINTENANCE

a. If th e engine is run w ith the air cl ean er. air
cleane r case cover or hose removed, fore ign
particl es entering w ill damage the turbine and
compresso r w hee ls beca use th ey rotat e at
ext remely high speeds.
e. W hen replacing t he t urbocharger, check for
th e acc umulat ion of carbon sludge in th e oil
pipes and, if necessary, clean out or replace
t he oil pipes.

b. If the turbocharger malfuncti on s and m ust be f. W hen replacing the turbochar ger, put 20cml
replaced, f irst check the foll owing item s for (0 .68 fl.oz.) of oil int o th e tu rbocharger oil inl et
th e cause of the problem and rem edy as and turn th e compressor w hee l by hand
necessary: several tim es to spread oil to the bearings.
• Engin e oil level and qu ality
• Conditions under wh ich the t urbocharger
was used
• Oil lin es leading to the turboc harger

c. Before remo ving the turbocharger, plug the

intake and exh aust port s and th e oil in let to
prevent t he entry of dir t or other for eign
mat erial.

d. Use cau tion w he n removin g and rein stalling

g. W hen overh auling or replacing the engine,
the t urbocharger assembly. Do not drop it or
cut th e fu el supply after reassemb ly and crank
bang it against anyt hing or grasp it by easily-
the engi ne for 30 seconds to distrib ute oil
deformed part s, such as the act uator or rod,
through out th e engine. Allow the engine to
w hen mov ing it .
idle for 60 seconds.

W RONG I

23
 INSPECTION OF TURBOCHARGER - On -vehi cle Inspecti on of Turbocharger

INSPECTION OF TURBOCHARGER

OBJECTIVES: - To master on-ve hicle inspect ion of the turboc harger

- To master off-vehicle inspect ion of the turbocharger
PREPARATIONS: - Turbochar ger assembly
- SST 09992 -00241 Turbocharger press ure gaug e
- Dial indi cator w / magnetic base
APPLICABL E ENGINE: 2L-T (J an uary, 1990)

ON-VEHICLE INSPECTION OF TURBOCHARGER

1 . IN SPECT A IR INTA KE SYSTEM
Check for leakage or clogging betw een th e air cleaner and
turboch arger inl et, and between the turb och arger outlet
and cylinder head.
If any problem is found, clean. repair or replace the part s.

2 . INSPECT EXHAUST SYSTEM

Check for leakage or clogging betw een the cylinder head
and turbocharger inlet, and betw een the tu rboch arger
outl et and exhaust pipe .
If any problem is found , clean, repair or replace th e part s.

SST Valve closed 3 . CH ECK ACTUATOR OPE RATION

(a) Discon nect th e actu ator hose.
(b) Using the SST (tu rbocharger pressure gau ge), apply
approx. 79 kPa (O.B' kgf/cm 2; 11.5 psi) of pressu re to
th e actuator and check t hat th e rod moves.
SST 09992-0024 1
If the rod does not move, replace t he tu rbocharger
assembly.
NOTICE: Never apply more t han 94 kPa (O.95kgfl
ern e: 13.5 psi) of pres sure to the actuator.

24
 INSPECTION OF TURBOCHA RGER - On-ve hicle Inspect ion of Tur bocharger

4 . CH ECK TURBOCHARGING PRESSURE

(a) Warm up the engin e.
(b) Connect a 3-way un ion to th e boost compensator
press ure hose and install the SST (tu rbocharger
pressur e gau ge) to it.
SST 09 992-00241
(c) Depress the clutc h pedal, th en press the accelerator
pedal down as far as it w ill go. M easur e t he turbo-
cha rging pressure at 2,400 rpm or more.
'--'''--'---'== - -'--'---''---- - OHP 15 Standard pre ssure:
60 - 7 9 kPa
(0.61 - 0 .81 kgf/cm ': 8 .7 - 11 .5 psi)
If th e pressure is less th an specificatio n, chec k the int ake
air and ex haust systems for leakage. If t here is no leakage,
replace the turbocharger assem bly.
If th e pre ssure is above spec if icat ion , check to see if the
actuator hose is di sconnected or cracked. If not, replace
the t urbochar ger assembly.

REFERENCE
W it h some engines. t he t urbocharging pressur e is checked
wh ile th e vehicle is runn ing. The fo llowing descr iption
exp lains how to check the t urbo ch arging pressure of th e 3S -
GTE engine (gasoline engine).
(a) Wa rm up th e engine.
(b) Using a 3-way connector, connect the SST (tu rbo-
charger pressur e gau ge) to the hose leading to t he
intake man ifold.
SST 09992 -0024 1
(c) W hile dr iving in 3rd gear w ith th e eng ine running at
2,800 rpm or more w ith the throttle valve fu lly open,
check th e tu rbochargin g pressure.
Standard pressure:
49-81 kPa
(0 .50 - 0 .83 kgf/ cm' : 7 .1 - 11 .8 psi)

OHP15

5 . CHEC K COMPRESSOR WHEEL ROTATION

(a) Disconn ect th e air clean er hose.
(bl Turn th e com pressor wheel by hand.
Check that it turn s smooth ly.
If it does not t urn , or if it drags w hile t urn ing, replace the
turbocharger assembly.

25
 INSPECTION OF TURBOCHARGER - Off-vehicle Inspect ion of Turbocharger

OFF-VEHICLE INSPECTION OF TURBOCHARGER

1. INSPECT AXIAL PLAY OF TURBINE SHAFT

fa) Insert the dial indicator into t he hol e of the turbin e
housing so that it contacts the end of the shaft.
(b) M oving the shaft in the axial direction. measure the
axial play of the shaft .
A xi al play: 0 .13 mm (O.OOSl in.) or less
If the axial play is not as specified. replace the t urboch arger
assembly.
2. INSPECT RADIAL PLAY OF TURBINE SHAFT
(a) From the oil outlet hol e. inse rt the dial indi cator
th rough t he hole in t he bearing spacer so th at it
contacts the center of th e turbine shaft.
(b) M oving th e turbine shaft up and down, measure th e
radial play of the shaft .
Radi al play : 0.18 mm (0 .0071 in.) or less
If th e rad ial play is not as specified. replace th e tu rbo -
ch arger assembly.

26
 SU PE RCHARGER -
SUPERCHARGER
DESCRIPTION
The supercharger, like the turbocharger, is a kind
of air pu mp w h ich forces much more air in t o t he
cylinders th an in th e case of an ordinary eng ine .
The Root s type supe rc ha rger used on the 4 A -GZE
~ ngi ne for th e MR2 (AW 11) is explained here.
To acti vate the supercharger. engine output is
tr ansm itt ed by a V-ribbed belt. via a cran kshaft
pu lley, to t he magn eti c cl utch. and f ina lly to the
two cocoon-shaped rotors ins ide the supercharger
housing.
Since it is driven dir ectl y by t he eng ine vi a a
cranksha ft pu lley and a V-r ibbed belt. the super -
charger sta rts providin g strong to rq ue at a low er
speed range tha n turboc hargers. Furt hermore, it s
time-lag is tess. th us ensu r ing a q ui ck respo nse.
Fuel injector
Intercooler
•
Crankshaft pulley
SUPERCHARGE R SYSTEM
(4A-GZE on MR Z lAW' ' 11
Descriptio n
The magn et ic cl utch is engaged and disengaged
by a signal from the Engine ECU according to the
run ni ng condit ions of the eng ine .
In the supercharger system, th ere is an air bypass
valve (A BV), which controls the amount of inta ke
air bypassing the supercharger, and an air contro l
valve (ACV), which contr ols t he introduction of
atmos pheric air into th e ventilation pipes to
prevent the leakage of the supercharger oil and
beari ng grease. These are also controlled by th e
Engin e ECU.
A n air-cooled type intercoo ler is provided to
improve charging efficiency. Operat ion of this
intercooler is the same as for the turbocharger
intercooler (see page 13 for deta ils).
A ir cleaner
- 0
Supercharger
ACV
OHP 16
27
C SUPERCHARGER Supercharger

CHARGER
SUPER netic clutc h.
The supercharger consists of aa mag
ears, .
housrng, a rear
two rotors, two rotor 9
plate. a rear cover, etc.

Ventilation pipes

Housing
Rotors

Oil level -"

gauge

Magnetic clutch
Magnetic clutch

From air cleaner

~_ _ _ __ _ _ ~
No.2 air inlet duct
if

~-~ 'f "'~

' .<...;i , ! Rear cover - - - - "- -e - - - - - - "'-- 1".1'
/
Rea ' p a Front cove'

:~ fJ;(j -
-, : RDtD'S _

,
No. 1
duet
in let/ ._'f/"; ~
._

~ --------
AB V \) ' <. ; . __ , .

~ .-: ~ c: -.....i:'~\fr3:l'.1A
To intake
manifold / '--'-..,,,,,..(1}) Hous tnq

No 1 a ir outlet duel
Magnelic clutch

CO N STRUC TION 0 F SUP ERCHARGER OHP 17

28
 SUPERCHARGER - Supe rcharger

1 . MAGNETIC CLUTCH

The ma gneti c clutch is tu rned on and off by the
Engin e ECU. It is turned off to stop th e super-
charger w he n th e engine is runn ing under a light
load.
The magnet ic clut ch consists of the clutc h stator,
th e clutch pu lley, and the clutch hub.
The clu tch pull ey turns around th e clutch hou sing
on a beari ng incorporated in the pull ey.
The clutch hu b is splined w ith th e rot or shah and
turn s as one com plete un it. There is a rubber
dampe r betw een t he boss of th e clu tch hub and
th e pressur e plate to allow th e plate to move in
Clutch housing
th e axial direct ion. W hen th e magnetic clu tch
turns on or off , the rubber damper absorbs the
shock that is created by the movem ent of the
plate.
The clutch stator is a solenoid. W hen the magnet ic
clutch is turned on, the pressure plate is pressed
against the clutch pu lley.
Norm all y, a 0 .5 mm (0.01 97 in.) clearance is
prov ided betw een the clutch hub and clutch
pulley , as shown. A larger clearance due to wea r,
etc ., may ca use noise. The clearance is adjusted
by changing the thickness of th e adjust ing shim.
Clutch pulley
Clutch stator

Clutch hub
Clutch hub

J~~~!~~~~R~ubber damper
Clutch stator
Pressure plate

Clutch housing
Clearance
OHP18

MAGNETIC CLUTCH CONTROL BY ENGINE ECU

The Engin e ECU turns th e magn et ic clutch on

under the following conditions: t
c
• Th rottl e valve ope ning ang le is more than a .Q
.3
certain angle (that is, during acceleration).
• Engin e speed and intake air vol ume per engine
revolution are in t he shaded area in the graph
-.
Eo
, >
0"
> •
" .cr,
c
.;0 M agnetic clutch off
to th e right (en gine under heavy load). • c
~ • L --'
ro "
.E~ Engine speed-e-e-

OHP 18

29
 SUPERCHARGER - Supercharger

2. ROTO RS AND HOUSI NG

A rotor and gear are fi tted to each of the tw o rotor The housing is made of alu minum. An air in let
shafts. w hic h are in turn fined to th e rear plate via duct is connected to the right and an air outlet
bearings. The rotors are made of aluminum. duct to the left . Bearings are located in th e f ront of
w hich is coated w ith a specia l fl uororesi n. the housing to support the roto r shafts .

Oil level gauge O-ring

Rotor s

Vent ilation pipe

I
Rotor gears ,~'--.:> Bearing s

Ventilat ion pipe

NOTICE - -- - - - -- - - - -- - - - - - - - - - - -----.,
The pair of rot ors are press-fit onto t he rotor
Rotor gears Rotors Rotor shafts
shafts and then fi xed in posi ti on by pin s and
serrations . Th e gears are pinne d integrally to
t he ro tor shaft so that the orig ina l ro to r-to -
rotor orientation will not be lost . For this
reason, t hey c annot be disassembled. Com - Pins
(for fixing
po nen t part s are t heref ore supp lied as an
gears)
assem bly, with rotors and gears f itted to t he
rear plate as ill ustrated .

Pins (for f ixing rotors)

30
 SUPERCHARGER - Supercharger

PUMP ACTION OF ROTORS

Pow er is transm itte d from the engi ne cranks haft ro tors turn in oppos ite directi ons and force air
pu lley to a V-ri bbed belt and the magnetic clutc h, between the housing and rotors as they rotate.
and fin all y to the lower rotor shaft. Th e upper and A ir is pumped out four ti mes per rot or revo lution.
low er rotor shafts are geared together. Th e two

\ 0
" ,
o

PUMP A CTiON OF ROTORS (viewed from rear) QHP 19

3. VENTILATION PIPES

The gears and rear bearings are lu bricated by

Toyota brand supercha rger oil. Th e front bearings Ventilation pipes
are lubri cat ed by grease.
The pressur e in th e hou sing varies w hile the
engine is operating . Vent ilation pipes are provided
to prevent oil leakage from the rear cover or
grease leakage fr om the front bearings du e to
pr essu re fluctu ati on. Introd uction of atmosphe re
into the vent ilation pipes is controlled by th e
ope n ing and closing of the air co ntrol valve (ACV).
(See page 38 for operation of t he A CV).
NOTICE
• Check o il lev el periodically (every 48.000
km [30 .000] m iles) or 36 months).
• Use Toyot a Supercharger Oi l (Part No.
08885·80108) or equivale nt.

31
 SUPERCHARGER - Ai r By-pass Valve

AIR BY-PASS VALVE (ABV)

1 . DESCRIPTION
An A BV is installed in the No. 1 air inlet duct . The The A BV opens and closes w hen the pressur e
passage bypassi ng the supercharg er is opened applied to the diaphragm of the A BV is shifted
and closed by it for the followi ng purposes: from atmospheric pressu re to vacuum and vice
• While t he engi ne is idli ng or operating un der a versa by the VSV . The VSV is tu rned on and off by
l ight load (l.e.• w he n the supercharger is off). the Engine ECU.
the supercharger will gene rate significan t
resistance to the flow of intake air.
The AB V prevents thi s by opening to ensure
the unimpeded flow of air in this sit uation.
• When the engine is accele rating (magnetic
clutch turns on), the rotors must be made to
sta n rotating slightly in advance of super-
charger operation to preve nt sudden charg ing .
• Whi le the engi ne is operating at hi gh speed.
the maximum boost pressure mu st be controlled
to prevent overcharging of the intake air. VTV vSV

EFI main relay

EFI
fuse Ignition, - L - j- -+_ -,
switch E .
nqme
ECU

':'" Various
signals
Supercharge

..
Air flow
meter
From air . .
T
•• cleaner ...:: \
~~::;:,__-_--- (Q~
To intake
manifold
~ Thrott le

1 valve

Mag netic clutch (:;~=====~--=[!;~Jl

Supercharger
relay

AIR BY-PASS VALVE SYSTEM

OHP 20

32
 SUPERCHARGER - Air By-pass Valve

2. CONSTRUCTION

The AB V cons ists of a valve that opens and closes

the bypass passage, and an act ua to r tha t open s
and closes this valve.
A ir released - -
Whe n atm ospheri c pressu re is introduced from
Chambe r A

-
the VSV into chamber A, this valve is closed by
th e diaph ragm spring.
Whe n vac uu m is introd uced fr om the VSV into
S upercharge r
cha mber A, th e di aphra gm shorte ns the dia- outlet side

-.
ph ragm sp ring, th er eb y opening the valve.
Va lve

Supercha rger
in let side

AIR BY-PASS VALVE OHP20

3 . ABV CONTROL BY ENGINE ECU

The VSV fo r the A BV is t urned on and off by t he

Engine ECU, in acco rdance with operat ion of the
supe rc ha rge r m ag netic cl utc h. en gine speed,
___ t hrott le valve opening ang le and open ing speed,
etc . W hen th e VSV is tu rned on , atmospheric
pr essure is introduced int o th e A BV and closes
th e valve.

The Engi ne ECU t urns th e VSV on under th e SUPERCHARGER MAGNETIC CLUTC H ON

fo llowing condit ions :
• Whe n the magneti c clutch is on, eng ine load is f
VSV on (ABV closed)
more th an an interm ediate level, and engine
speed is a little below th e maximum speed.
VSV off (ABV 0 en)
• W he n th e magn eti c cl utc h is off, and eng ine
speed is greate r than me dium spee d. Engine speed _

W he n th e starte r signa l is detected or th e coo lant SUPERCHARGER MAGNETIC CLUTC H OFF

te mperatu re is low, th e VSV is t urned off a uto-
VSVoH VSVon
mat ically regardless of the above conditions. (A BV open) (ABV closed)

Engine speed -

OHP20

33
 SUPERCHARGER Air By-pass Valve

4 . OPERATION

d) SUPERCHARGER OFF (PHASE 11 (2) SUPERCHARGER OFF (PHASE 2)

The superch arger is off w hi le the engine is idling
or oper ating under a light load.
Since th e superc harger magnetic cl utch an d VSV
are turned off by th e Engine ECU. vacuu m acts on
chamber A of t he AB V and opens t he valve .
Therefore. most of the intake air bypasses th e
supercha rger and is introduced into the intake
ma nifold th roug h the AB V.
W hen th e eng ine is run nin g un der a light load
and abov e medium speed. th e VSV w ill go on
w hite the superc harger magnetic cl utch remains
off. In this event, since the VSV is on. atmosph eri c
pressure is introduced into chamber A of th e AB V
and closes th e valve. Therefore. intake air causes
the rotors to spi n. afte r w hich it is introduced
(without bei ng comp ressed) into th e intake mani -
fold via th e supercharger.
Th is prevents, for exam ple, sudden operat ion of
the superch arger just before the magne tic cl utch
turns on w hen the engine beg ins acce lerat ing.
(This is to reduce the operat ing shoc k of the
clutch.)

ABV (closed)

~
Chamber A

Supercharqer Superc harger

\
Throttl e
valve
..
Intercooler

Thrott le
valve
..
Int ercooler

Magnetic 1:T~;::=====
clutch ~ MagnetiC
clut ch 8':~======
~
loffl (olfl

OHP 2 1
OHP 2 1

34
 SUPERCHARGER - Ai r By-pass Valve

~) SU PERC HARGER TUR N ED O N ® DUR ING OV ER -CHARGING

The supercha rger is on as long as the engine is
accelerating or operating under a heavy loa d.
Since the supe rcha rger magnetic cl utch and the
VSV are tu rned on by the Engine ECU. the AB V
closes because atmosphe ric pressure is lntro-
duced from the VSV into chamber A of the ABV.
All intake air is sent to the supe rcha rger and
pressu rized th erebefore being introduced into the
intake ma nifold.
A s the engine speed increases, the supercharging
pre ssure rise s. When the engine speed increases
to around maximum rpm , the Engin e ECU turn s
the VSVoff and a w eak vac uum acts on ch amber
A of the A BV. At the same t ime, part of the
supercharging pressure act s on the upper side of
the A BV valve and attempts to pus h it open . The
valve is fi nally opened by t hese tw o forces and
part of th e supe rcharged air returns to the air inlet
duct. The result is that boost pressur e is low ered.

VSV (on) ABV (closed) VSV lo ff ) A BV (open)

Cha mbe r A ~Chamber A

Suo ercharq ej
Intercool er
r. JSupercha rge r
I
o

Thrott le Throttle
valve va lve
MagnetiC'~
clutch ~ ~r.~~===== Magn etic 'i;~.·C~=====
clutch
(ani (on)

OHP22
OHP22
REFERENC E
Duri ng sudden decel eration, the Engine ECU
turns the VSV off , and the ABV opens . This
causes unnecessary supercharged air to be
returne d to the inlet side of the supercharger.

35
 SUPERCHARGER - A ir By-pass Valve

REFERE NCE - - - - - - - - - - - - - - - -- - - - - - - - - - -r-r--,

2TZ-FZE ENGINE FOR RREVIA ITCR101

Th e supercharg er system of the 2TZ-FZE en-
gine i nt roduced in A ugust 1994 is basica lly t he
same as th at of t he 4A~GZE engine, except for
t he fo llow i ng tw o point s:
• The byp ass valve has been chan ged fr om
th e ON-OFF typ e to t he li near typ e and has
be en ma de to o utput t he engi ne t orq u e in
p ro p ort ion to th e o p en ing an gl e o f th e
throttl e va lv e.
• The supe rc harger is dri v en direct ly by t he
engine pow er vi a a drive shaft as it is in-
cluded i n the sepa rate accessory syste m .

System Diagram

M agnetic clutc h relay

S uperc ha rg er
bypass v al ve

J'~I-----1 I--

1 - !lU.IJIJt: m anifold
I------;;J
A ir cleane r

Charge air coo ler

[Interco o ler ]
-<lilt- Int ake air f low

36
 SU PERCHARGER - Air By-pass Valve

Sup ercharger Bypass Valve

By adopti ng th e by pass va lve of a steppe r mo-
to r type, air vo lu me by pass ing the super-
cha rge r ca n be co ntrolled lin ear ly.
As a res u lt. the di scharg e rate of t he supe r-
Bypass air
charger ca n be co ntrolle d linearly.
The ste pper m ot o r trpe supe rc ha rger bypass
va lve co ns ists of a stepper moto r, w hic h is u n-
de r t he direct co ntrol of th e Engine ECU, and a
va lve th at is d riven by gear s. In accorda nce
w it h th e ru nning co nd it io n of th e eng ine. t he
Eng in e ECU co ntrols t he ste pper m otor t o reg -
ul ate the amo unt of intake ai r to bypass and
t hus op tim ize th e supe rc harger disc harge rate.
Com pa red to the 4A -GZE engine w hich uses a
Steppe r motor Gear Valve
vac u um type supercharge r by pass va lve. th e
present 2TZ-FZE en g ine w it h th e ste ppe r moto r
t y pe supercha rger bypass va lve can pro duce
torq ue that is m ore linear in relatio n t o th e
t hro tt le ope ning ang le.

Separated A ccessory Drive System

-- Engine

Dri ve shaft

.--
, ,,-- -
I, . . •

«"
'
-' \

Super charger

V-Ribbed belt (f or supe rcha rger)

37
 SUPERCHARGER - A ir Contro l Valve

A IR CO NTROL VALVE (AC VI

The A CV is t urn ed on and off by the Engine ECU. To rear From air intake
vent ilat ion connecto r
Wh en it is tu rned on. atmospheri c air is sen t int o pipe
the ventilat ion pipes located in the front and rear
of the supercharger. A s a result . the pressure
nea r the front and rear bearing s becom es clo se to
atmospheric pressure. This prevents grease fo r
th e front beari ngs and oi l for the rear bearin gs
and gears from leaking out due to pressure
flu ctuat ion s inside the supercharger ho us ing.

To fr ont ventilation pipes

OHP23
EFI ma in rel ay

EFI Ignition
fuse ACV
switch Engine (on)
ECU

Ventilat ion
1I-_- -1f7 pipes
.
To supercharge r
L

.
•

I
AI R CONTROL VALVE SYSTEM OHP23

ACV CONTROL BY ENGINE ECU

The Engine ECU turns the ACV on un der the

1r-------~~
ACV off
followi ng conditions:
• Engine speed and engine load are in the
shaded area in the diagram to the right .
• The en gine is starting.

Engine speed _

OHP23

38
 INSPECTION OF SUPERCHARGER - On -vehicle Inspecti on of Superc ha rger

INSPECTION OF SUPERCHARGER

OBJECTIVES: • To master on-veh icle inspection of th e supercharger.

• To master the fo llowing items:
• Inspect ion of air by-pass valve and VSV
• Inspect ion of air cont rol valve
• Replacem ent of clutch stato r
PREPA RATIONS: • Supercha rger assembly
• SST 09504 ~OOOl l Different ial side bearing adju sting nut w rench
098 14 -2201 0 Rear wiper pivot shaft lock nut w rench (for removing
clutch pu lley ring n ut )
09992-0024 1 Turbocharger pressure gauge
• Snap ring pliers (for replacing magn etic clutc h stato r)
• Dial indicator w / mag netic base
• " M ITYVAC ' (hand-held vacuum pump)
• Circu it tester (volt- and oh mm eter. m ult i-tester)
• Toyota superc harger oi l (08885-80 108)
A PPLICABLE ENGINE: 4 A -GZE on MR2 IAW11) [Aug.. 19871

ON -VEHICLE INSPECTION OF SUPERCHARGER

r. CHECK SUPERCHARGER OIL LEVEL
HINT: W ith th e engine cold, check the oil level in th e
supercha rger w ith th e dipstick .
(a) Park the vehicle on a level spot and turn the engine
off .
(b) Turn t he yellow-headed supercharger oi l level dipst ick
counte rcloc kwise and pu ll it out.
(c) W ipe the dipsti ck clean wit h a rag.
Painted yellow (d) Rein sert t he dipst ick. Turn it fu lly clockw ise or t he
reading w ill not be correct.
(e) Remove th e dipst ick aga in and look at t he oil level on
t he end.
(f) The oil level sho uld be betw een the " L" and " F"
marks on th e dipstick.
If low , check for leakage and add oil up to the " F" mark as
follow s:
(g) Ad d supercha rge r oil though the dipsti ck tube using a
viny l tube and syringe.
Supercharger oil: Part No. 08885 ~801 08 or equivalent
Syringe
(h) Recheck the oil level.
NOTICE: Avoid under- or overfilling, or the su per-
charger could be damag ed .

' - -- - -'-- - -- -IOHP 24

39
 INSPECTION OF SU PERC HA RGER - On-vehi cle Inspection of Supercharge r

2. CHA NGE SUPERCHARGER OIL IF NECESSA RY

(a) Rem ove th e magneti c pl ug at the botto m of the rear
cover and drain the oil.
(b) Crean and install t he magnetic plug w it h a new
gasket.
(c) Fill the super charge r w ith new oil.
S upercharge r oil :
Part No. 0 8885-80108 or equivalent
Oi l capacity: 130 cc (4 .4 f l.oz.)

Ohmmeter 3. IN SPECT M A GNETIC CLUTCH

r «: (a) Check th at the magnetic crutch goes on w hen the

IO~
thrott le valve is suddenly opened during engine
idling.
(b) Using 'an ohm meter, meas ure t he resistance of th e
stator coil betwee n the clutch lead w ire terminals.
St andard resistance: 3 .7 ± 0 .2 n at 20 °C (68 °FI
If t he resi stance is not as specified, replace th e clutc h
stato r.

4 . INSP ECT AI R BY·PASS VALVE (ABVj

~kf~- W it h the engine idling, disconnect the A BV vac uum hose

and check th at there is norma l operating noise in the AB V.
If no operat ing noise is heard, inspect the ABV and the
::::::- ".. . XV1}{}i),~
a~~)\ · .~lJ,'s~~fl
VSV separately .

ABV II It
I \
, -~~
'vsv

5 . CHEC K SUPERCHARGER PRESSURE

(a) Install t he SST (t urb och arger pre ssure gau ge) be-
tw een t he VSV (fo r fue l pressure regu lator) and the
intake ma nifold with a three -way jo int.
SST 09992-00241
(b) (MIT veh icle s)
W hile dri vi ng in 4th gear wit h the engine running at
1,500 rpm , f ully open the throttle valve and check the
supercharger pressure w ith the engi ne rpm at 2,000
rpm. .
Standard pressure : 25 kPa (0 .25 kg f / cm 2 , 3 .6 p si)
(e) (A/T veh icle s)
Check the supe rcha rger press ure by perform ing a
stall test .
Standard pressure: 2 9 kP a (0 .30 kgflcm 2• 4 .3 psi)
If the press ure is less than specified, inspec t the super-
cha rger assembly.
If the pressure is above specif icat ion, inspect the ABV
system.

40
 INSPECTION OF SUPERCHARGER _ Inspect ion of ABV and VSV
Inspect ion of A CV

INSPECTION OF ABV AND VSV

ABV
1. INSPECT AIR BY·PASS VALVE (ABVI
Apply a vacuu m to the AB V and measu re the vac uum
w he n the valve ope ns.
Vacuum (val ve partially open ):
13 .00 - 21 .99 kPa
(10 5 - 1 6 5 mmH9; 4 .134 - 6 .496 in .Hql
Vacuum (valve fu lly open):
32.66 - 52.65 kPa
L - -- - - - ---="---- - OHP 24
(245 - 395 mmHg; 9 .646 - 1 5 .5 5 1 in.Hg)
If th e vacuum is not w it hin specific ation, replace the A BV.

2. INSPECT VSV FOR ABV

(a) Appl y battery voltage across t he terminal s.
(b) Check th at air flow s fr om pipe E to the air fi lter.

e (jl
Batte ry

(e) Disconnect t he batt er y term inals.

(d) Check that air fl ow s from pipe E to pipe G.
If a prob lem is found, replace th e VSV ,

1 C7:}~ G
- ), e EEl
~
~)
" Battery

INSPECTION OF ACV
(a) A pply battery voltage across the term inals.
(b) Chec k th at air fl ow s fr om pipe A to pipes B and C.

e (jl
Battery

(e) Discon nect th e batter y termina ls.

(d) Check th at air does not flow fro m pipe A to pipe B or
C.

~!Y
If a problem is fo und, replace th e ACV.

> -
- '\ ' .'.,

B
e EEl
Batte ry
C

41
 INSPECTION OF SUPERCHARGER - Replacement of Clutch Stator

REPLACEMENT OF CLUTCH STATOR

1. REMOVE CLUTCH HUB
Using the SST, remov e t he nu t, clutch hub. and shi m.

2. REMOVE CLUTCH PULLEY

[a) Using the SST. re move th e ring nut.
SST09 814-220 10
(b) Remove the clutch pu lley and sh im .

3. REMOVE CLUTCH STATOR

(a) Disconnect the connecto r from the clamp.
(b) Using snap ri ng pli ers. remove the snap ring.
(c) Remove the clutch stator.

4 . INSTALL CLUTCH STATOR

la ) A lign the hole of th e clutch flange with the protru sion
of the clutch stator.

(b) Usin g snap ring pliers. install the snap ring . facing the
tapered side towa rd the front.

42
INSPECTION OF SUPERCHARGER - Replacement of Clutch Stator

5 . INSTALL CLUTCH PULLEY

la) Install the clutc h pulley.
SST (b) Using the SST. install the ri ng nu t.
SST 098 14·22010
Torque: 2 5 N ·m (2 50 kg-em; 18 ft-Ib)

6 . INSTALL CLUTCH HUB

(a) On t he shaft in sta ll the shim used previously. the n
insta ll the clutch hu b.
(b) Using the SST, in stall and t ighten the nut.
SST 09504·00011
Torque; 20 N ·m (200 kg- em ; 14 ft-Ib)

7 . CHECK AND ADJUST AIR GAP OF MAGNETIC

CLUTCH
(a) Set up a dia l indica to r as shown in the illustrat ion .
(b) Place mat chma rks to ensure that the relative positions
of the pulley and clutch hub remain unchanged.
(e) A pply battery volta ge between th e term inals of th e
connector, and measure the amount of axial move-
ment of the clutch hub.
NOTE: Take measurements starti ng f rom the second or
third time the cl utch hub is operated.
(d) M easure the ot her three locat ions using t he same
met hod. Take the average value for th e fou r locat ions
and use it as the air gap value.
NOTE: W hen measuring, check that the matchmarks for
the pulley and d utch hub are al igned.
Standard air gap: 0 .35 - 0 .65 mm
(0 .0138 - 0 .0256 ;n.)
If th e air gap is not within specif ication, replace t he shim.

Ad just ing shi m thickn ess m m (in .)

0.1 10.004) 0.7 10.028)

0.310.012} 0.9 10.035}
0.5 10.0201 t.1 10.0431

If the air gap is greater than specified, use a thin ner sh im.
If the air gap is less than specified, use a thicker shi m.

43