1. Welcome to AfterSalesTraining

2. Comfort & Convenience Coffee Breaks Lunch Arrangements Telephones Messages Start & Finish Times Toilets Smoking Policy Fire Precautions

3. Applications 150 Ps Rover 75 160 Ps MG ZT 160 Ps MG ZT-T

4. Rover 75 150 Ps 4 Cylinder Turbocharged K Series 150 Ps engine Getrag 5 speed manual transmission JATCO automatic transmission Unique turbo exhaust system

5. 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

6. Why change?

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

8. K Series Exploded View

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

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

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

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

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

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

15. Engine Enhancements Throttle body Breather system

16. Part load breather Breather valve Full load breather

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

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

19. Front Pipe Bracket

20. Turbocharger Location

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

22. History

23. 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 20000 rpm to over 150000 rpm in less than 1 second!

24. Facts! Air entering a turbo compressor impellor can be travelling @ Mach 1! Turbo blades will travel in the region of 820 mph at average engine speed! New generation turbos can rotate up to 220000 rpm – a 747 jet engine rotates at @ 7000 rpm!

25. Turbo Components 1 2 3 4 5 1.Turbine wheel 2.Turbine housing 3.Bearing housing 4.Compressor wheel 5.Compressor housing 6.Wastegate actuator 6

32. Turbocharger Components

33. Turbocharger

34. Turbo Operation Exhaust gas drives turbine Compressor pressurises inlet air

35. Turbo Schematic

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

37. Boost Modulation Valve

38. Boost Modulation Valve Location

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

40. Thermo Syphon Cooling

41. Turbocharger damage

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

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

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

45. 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

46. 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

47. 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

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

49. 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

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

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

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

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

54. Engine Management Inputs Gear Position Signal Gearbox Output Shaft Speed Signal

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

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

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

58. T4 Practical Tasks

59. Pressure Testing

60. 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

61. 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.

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

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

64. 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

65. Vacuum Fill

66. 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

67. Vacuum Fill Fit adapter to expansion tank neck

68. Vacuum Fill Ensure both stop valves are closed V1 V2

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

70. 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

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

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

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

74. 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)

75. 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