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Applications 150 Ps Rover Ps MG ZT 160 Ps MG ZT-T

Rover Ps 4 Cylinder Turbocharged K Series 150 Ps engine Getrag 5 speed manual transmission JATCO automatic transmission Unique turbo exhaust system

MG ZT ZT-T 160 Ps 4 Cylinder Turbocharged K series 160 Ps engine 5 Speed Getrag manual gearbox (4.167 final drive) Unique Turbo exhaust system

Why change?

K Series Engine 4 cylinder 16 valve Launched 1989 Available 1.4, 1.6, 1.8 Through bolt construction

K Series Exploded View

Engine Enhancements Lowered compression ratio 9.2:1 Connecting rod bearing material change New block and bearing ladder castings Steel sump gasket

Engine Enhancements Exhaust manifold material change Quick fit coolant hose connectors Cooling system stub pipes Oil filter housing

Engine Enhancements Engine block to bearing ladder sealant Fuel injection rail Fuel demand regulator

Fuel Rail Forged alloy Incorporates locating dimples Fuel demand regulator Schrader valve

Engine Enhancements Engine block to bearing ladder sealant Fuel injection rail Fuel demand regulator Injectors

Injector Bosch high flow rate 20º spray pattern Unique locating dimple

Engine Enhancements Throttle body Breather system

Part load breather Breather valve Full load breather

Engine Enhancements Throttle body Breather system Temperature Manifold Pressure Sensor (TMAP) Oil pump

Engine Enhancements Dual mass flywheel Uprated clutch Wiring harness 2 piece exhaust system

Front Pipe Bracket

Turbocharger Location

Why Turbocharge? Allows small engines to produce up to 40% more power Reduce emissions Increase fuel economy Prevent power loss at high altitudes

History

Facts! The average temperature of exhaust gas entering the turbo can be up to 1000ºC – hot enough to melt glass! At average speeds a medium size turbo can swallow 130 cubic feet of air – equivalent to the interior volume of a Transit! A turbo will accelerate from rpm to over rpm in less than 1 second!

Facts! Air entering a turbo compressor impellor can be Mach 1! Turbo blades will travel in the region of 820 mph at average engine speed! New generation turbos can rotate up to rpm – a 747 jet engine rotates 7000 rpm!

Turbo Components Turbine wheel 2.Turbine housing 3.Bearing housing 4.Compressor wheel 5.Compressor housing 6.Wastegate actuator 6

Turbocharger Components

Turbocharger

Turbo Operation Exhaust gas drives turbine Compressor pressurises inlet air

Turbo Schematic

Boost Modulation Valve From Air Cleaner To Wastegate Capsule From Compressor Housing

Boost Modulation Valve

Boost Modulation Valve Location

Lubrication Oil pressure feed Turbine Compressor Oil drain Oil squirt for added cooling

Thermo Syphon Cooling

Turbocharger damage

Power Loss/Black Smoke Restricted air flow Air leaks in pressure circuit Blocked or restricted exhaust Seized turbo shaft Damaged turbine or compressor blades

Blue Smoke Restricted air flow Damaged turbo shaft seals Excessive crankcase pressure Turbo oil drain restriction

Noisy Operation Pressure leaks Damage to turbine or compressor blades Seized turbo shaft

Operating Precautions Never immerse the turbocharger in solvent when cleaning Never increase engine speed before switching it off Never operate the engine with the turbo pipes disconnected

Operating Precautions Never attempt to visually inspect the turbocharger with the engine running Always adhere to service intervals Avoid excessive engine speeds directly after starting

Operating Precautions Always use recommended parts (oil and filters) Never carry out any unauthorised adjustments Only ever use recommended sealants Always prime oil filter before fitment

Engine Management Requirements? Must comply with any anti pollutant legislation Must meet customers requirements for easy operation Must be extremely reliable with minimal maintenance

Engine Management Requirements? Must give smooth driving capability Must be as economical as possible Must be as powerful as possible Must be as quiet as possible

Engine Management Inputs Crankshaft Sensor Camshaft Sensor Throttle Position Sensor Coolant Temperature Sensor Oil Temperature Sensor

Engine Management Inputs Temperature, Manifold Absolute Pressure (TMAP) Sensor Air Intake Temperature Sensor Ambient Air Temperature Sensor Upstream & Downstream Oxygen Sensors Trinary Switch

Engine Management Inputs Evaporator Temperature Sensor Fuel Tank Level Signal Alternator Load Signal Inertia Switch Immobilisation Signal

Engine Management Inputs Ignition Switch Signal Air Conditioning Request Signal Vehicle Speed Signal Rough Road Signal Torque Reduction Signal

Engine Management Inputs Gear Position Signal Gearbox Output Shaft Speed Signal

Engine Management Outputs Stepper Motor Purge Valve Oxygen Sensor Heaters Ignition Coils Injectors

Engine Management Outputs Air Conditioning Relay Engine Cooling Fan Temperature Gauge Tachometer Drive Malfunction Indicator Light

Engine Management Outputs Turbo Boost Modulator Valve Main Relay Fuel Pump Relay Engine Information to Gearbox ECU (Automatic Only)

T4 Practical Tasks

Pressure Testing

Visually check engine and cooling system for signs of coolant leaks. Examine hoses for signs of cracking, distortion and security of connections. Position heater temperature control to maximum heat position. Remove expansion tank filler cap

Pressure Testing Connect pressure hose to adaptor. Position pressure pump, connect pressure hose to pump. Slowly pump up system to required pressure and check for leaks.

Pressure Testing Release pressure by depressing pressure release valve on pump.

Pressure Testing Remove pump from pressure hose. Remove hose from adaptor. Remove adaptor from expansion tank and refit expansion tank filler cap.

Pressure Cap Testing Select correct adapter and fit cap Connect pressure hose to adapter and pump Slowly pressurise cap until correct pressure obtained and held

Vacuum Fill

Vacuum Fill Preliminary Checks Empty expansion tank Check cooling system capacity Sufficient coolant supply available Compressed air supply (6 to 10 bar) Set heater controls to hot

Vacuum Fill Fit adapter to expansion tank neck

Vacuum Fill Ensure both stop valves are closed V1 V2

Vacuum Fill Connect valve block to adapter Connect venturi to valve block

Vacuum Fill Preparation Connect air supply (8 to 10 bar) Immerse filling tube into fresh coolant Open both valves Bleed until filling tube is air bubble free

Vacuum Fill Evacuation Close filling tube valve (V1) Allow vacuum build up (0.85 to 0.9 bar- green zone) V1

Vacuum Fill Evacuation Close stop cock (V2) Remove air supply V2

Vacuum Fill Leak Test Leave for 1 minute If vacuum drops – leak If vacuum remains - proceed

Vacuum Fill Filling System Immerse filling tube in prepared coolant and open filling tube valve (V1) Fill expansion tank to max level Residual vacuum released by opening stopcock (V2)

Vacuum Fill Level Check Coolant level may drop after refill due to relaxing hoses Start engine and allow coolant to circulate Recheck level and top up when engine cooled