1. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Welcome to AfterSalesTraining

2. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE R505 4 Cylinder Pressure Charged Engine Steve Baker

3. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Comfort & Convenience Coffee Breaks Lunch Arrangements Telephones Messages Start & Finish Times Toilets Smoking Policy Fire Precautions

4. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Introduction Course Code : R505 Course Title : 4 Cylinder Pressure Charged Engine Course Duration : 1 Day

5. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Applications 150 Ps Rover 75 160 Ps MG ZT (proposed) 160 Ps MG ZT-T (proposed)

6. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Rover 75 150 Ps 4 Cylinder Turbocharged K Series 150 Ps engine Getrag 5 speed manual transmission JATCO automatic transmission Unique turbo exhaust system

7. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Why Change? Company car markets CO 2 output 193 g/km compared to 232 g/km (2.0 KV6) Fuel consumption 15% combined fuel economy improvement

8. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Why Change? Improved acceleration up to 0.5 seconds quicker 0 to 60 mph At least 50 Kg lighter 16% increase in torque at lower engine speed 215 Nm @ 2500 rpm vs 4000 rpm

9. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE K Series Engine 4 cylinder 16 valve Launched 1989 Available 1.4, 1.6, 1.8 Through bolt construction

10. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE K Series Exploded View

11. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Engine Enhancements Lowered compression ratio 9.2:1 Connecting rod bearing material change New block and bearing ladder castings Steel sump gasket

12. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Engine Enhancements Quick fit coolant hose connectors Cooling system stub pipes Exhaust manifold material change

13. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Quick Fit Connectors

14. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Quick Fit Connectors

15. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Engine Enhancements Exhaust manifold material change Quick fit coolant hose connectors Cooling system stub pipes Oil filter housing

16. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Engine Enhancements Fuel injection rail Fuel demand regulator Engine block to bearing ladder sealant

17. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Fuel Rail Forged alloy Incorporates locating dimples Fuel demand regulator Schrader valve

18. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Engine Enhancements Engine block to bearing ladder sealant Fuel injection rail Fuel demand regulator Injectors

19. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Injector Bosch high flow rate 20º spray pattern Unique locating dimple

20. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Engine Enhancements Breather system Throttle body

21. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Part load breather Breather valve Full load breather

22. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Engine Enhancements Throttle body Breather system Temperature Manifold Pressure Sensor (TMAP) Oil pump

23. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Engine Enhancements Uprated clutch Wiring harness 2 piece exhaust system Dual mass flywheel

24. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Front Pipe Bracket

25. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Turbocharger Location

26. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Why Turbocharge? Allows small engines to produce up to 40% more power Reduce emissions Increase fuel economy Prevent power loss at high altitudes

27. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE 1900’s 1910’s 1920’s1930’s1940’s1950’s1960’s1970’s1980’s1990’s

28. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE 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 per minute – equivalent to the interior volume of a Transit! A turbo will accelerate from 20,000 rpm to over 150,000 rpm in less than 1 second!

29. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE 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!

30. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Turbo Components 1 2 3 4 5 1.Turbine wheel 6

31. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE

32. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Turbo Components 1 2 3 4 5 1.Turbine wheel 2.Turbine housing 6

33. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE

34. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Turbo Components 1 2 3 4 5 1.Turbine wheel 2.Turbine housing 3.Bearing housing 6

35. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE

36. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Turbo Components 1 2 3 4 5 1.Turbine wheel 2.Turbine housing 3.Bearing housing 4.Compressor wheel 6

37. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE

38. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Turbo Components 1 2 3 4 5 1.Turbine wheel 2.Turbine housing 3.Bearing housing 4.Compressor wheel 5.Compressor housing 6

39. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE

40. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE 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

41. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE

42. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Turbocharger Components

43. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Turbocharger

44. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Turbo Operation Exhaust gas drives turbine Compressor pressurises inlet air

45. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Turbo Schematic

46. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Boost Modulation Valve From Air Cleaner To Wastegate Capsule From Compressor Housing

47. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Boost Modulation Valve

48. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Boost Modulation Valve Location

49. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Lubrication Oil pressure feed Turbine Compressor Oil drain Oil squirt for added cooling

50. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Thermo Syphon Cooling

51. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Turbocharger Damage Lubrication issues Foreign object damage Operational temperature extremes

52. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Power Loss/Black Smoke Restricted air flow Air leaks in pressure circuit Blocked or restricted exhaust Seized turbo shaft Damaged turbine or compressor blades

53. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Blue Smoke Restricted air flow Damaged turbo shaft seals Excessive crankcase pressure Turbo oil drain restriction

54. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Noisy Operation Pressure leaks Damage to turbine or compressor blades Seized turbo shaft

55. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE 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

56. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Operating Precautions Always adhere to service intervals Avoid excessive engine speeds directly after starting Never attempt to visually inspect the turbocharger with the engine running

57. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Operating Precautions Never carry out any unauthorised adjustments Only ever use recommended sealants Always prime oil filter before fitment Always use recommended parts (oil and filters)

58. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Engine Management Requirements? Must comply with any anti pollutant legislation Must meet customers requirements for easy operation Must be extremely reliable with minimal maintenance

59. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Engine Management Requirements? Must be as economical as possible Must be as powerful as possible Must be as quiet as possible Must give smooth driving capability

60. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Engine Management Inputs Crankshaft Sensor Camshaft Sensor Throttle Position Sensor Coolant Temperature Sensor Oil Temperature Sensor

61. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Engine Management Inputs Temperature, Manifold Pressure (TMAP) Sensor Ambient Air Temperature Sensor Upstream & Downstream Oxygen Sensors Trinary Switch

62. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Engine Management Inputs Evaporator Temperature Sensor Fuel Tank Level Signal Alternator Load Signal Inertia Switch Immobilisation Signal

63. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Engine Management Inputs Ignition Switch Signal Air Conditioning Request Signal Vehicle Speed Signal Rough Road Signal Torque Reduction Signal

64. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Engine Management Inputs Gear Position Signal Gearbox Output Shaft Speed Signal

65. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Engine Management Outputs Stepper Motor Purge Valve Oxygen Sensor Heaters Ignition Coils Injectors

66. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Engine Management Outputs Air Conditioning Relay Engine Cooling Fan Temperature Gauge Tachometer Drive Malfunction Indicator Light

67. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Engine Management Outputs Turbo Boost Modulator Valve Main Relay Fuel Pump Relay Engine Information to Gearbox ECU (Automatic Only)

68. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE

69. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Pressure Testing

70. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE 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

71. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE 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 to be held for 3 minutes).

72. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Pressure Testing Release pressure by depressing pressure release valve on pump.

73. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Pressure Testing Remove pump from pressure hose. Remove hose from adaptor. Remove adaptor from expansion tank and refit expansion tank filler cap if pressure cap test satisfactory.

74. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE 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

75. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Pressure Cap Testing Release pressure Remove pressure cap

76. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Cap Pressures ModelEngine typePressure Rover 25 / MG ZR1.4 1.6 1.8 K Series0.9 to 1.2 bar 2.0 L Series Diesel0.9 to 1.2 bar Rover 45 / MG ZS1.4 1.6 K Series0.9 to 1.2 bar 1.8 K Series0.9 to 1.2 bar 2.0 2.5 KV61.1 to 1.5 bar 2.0 L Series Diesel0.9 to 1.2 bar Rover 75 / MG ZT1.8 K Series0.9 to 1.2 bar 2.0 2.5 KV60.9 to 1.2 bar 2.0 M47R Diesel1.1 to 1.5 bar MG F / MG TF1.8 1.8 VVC K Series0.9 to 1.2 bar

77. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Vacuum Fill

78. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE 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

79. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Vacuum Fill Fit adapter to expansion tank neck

80. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Vacuum Fill Ensure both stop valves are closed V1 V2

81. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Vacuum Fill Connect valve block to adapter Connect venturi to valve block

82. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE 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

83. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Vacuum Fill Evacuation Close filling tube valve (V1) Allow vacuum build up (0.85 to 0.9 bar- green zone) V1

84. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Vacuum Fill Evacuation Close stop cock (V2) Remove air supply V2

85. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Vacuum Fill Leak Test Leave for 1 minute If vacuum drops – leak If vacuum remains - proceed

86. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE Vacuum Fill Filling System Open filling tube valve (V1) Fill expansion tank to max level Residual vacuum released by opening stopcock (V2)

87. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE 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

88. R 505 4 Cylinder Pressure Charged Engine 30 June 2016 AfterSalesTraining RAVE