INTAKE SYSTEM


  1. CONSTRUCTION


    1. Intake Manifold


      1. An intake manifold made of plastic is used.

      2. An EGR passage, swirl control valve, actuator (for swirl control) and swirl control valve position sensor are provided in the intake manifold.

        A004M0IE02
        Text in Illustration
        *1 Intake Manifold *2 Gasket
        *3 Swirl Control Valve *4 Actuator (for Swirl Control) and Swirl Control Valve Position Sensor Portion
        *a EGR Passage - -

    2. Diesel Throttle Body Assembly


      1. A diesel throttle body assembly equipped with a DC motor type throttle control motor is used. The DC motor is controlled in accordance with the ECM signals.

      2. A throttle position sensor is installed in the diesel throttle body assembly.

        A004M2ME01
        Text in Illustration
        *1 Diesel Throttle Body Assembly *2 Diesel Throttle Valve
        *3 Throttle Control Motor - -
        *a Throttle Position Sensor Portion - -
        A004LMN Intake Air - -

    3. Intercooler Assembly


      1. An air-cooled intercooler is used in order to lower the intake air temperature, improve engine performance, and achieve cleaner exhaust gas emissions.

      2. The intercooler is made of aluminum.

        A004MBPE01
        Text in Illustration
        *1 Intercooler Assembly - -

    4. Air Cleaner Assembly


      1. A quick connector is used to connect the turbocharger sub-assembly and the air cleaner hose assembly in order to improve serviceability. The hose can now be connected and disconnected without using any tool.

        A004MBKE02
        Text in Illustration
        *1 Air Cleaner Hose Assembly *2 Ventilation Hose
        *3 Intake Mass Air Flow Meter Sub-assembly *4 Air Cleaner Cap Sub-assembly
        *5 Air Cleaner Filter Element Sub-assembly *6 Air Cleaner Case Sub-assembly
        *a Quick Connector - -

    5. Compressor Outlet Elbow


      1. A quick connector is used to connect the turbocharger sub-assembly and the compressor outlet elbow in order to improve serviceability. The hose can now be connected and disconnected without using any tool.

        A004M7NE02
        Text in Illustration
        *1 Turbocharger Sub-assembly *2 Compressor Outlet Elbow
        *a Quick Connector - -

    6. Turbocharger Sub-assembly


      1. A variable nozzle vane type turbocharger is used.

      2. The variable nozzle vane type turbocharger consists primarily of a compressor wheel, turbine wheel, nozzle vane, unison ring, drive arm, driven arm, actuator (motor and nozzle vane position sensor) and linkage.

      3. This turbocharger has achieved great improvements in low-speed torque, maximum output, fuel consumption and emission reduction. These improvements have been accomplished through variable control of the nozzle vane position, and maintenance of an optimal velocity of the exhaust gas inflow to the turbine at all times in response to the engine condition.

      4. The ECM outputs a signal to the turbocharger sub-assembly, which operates the actuator, to control the nozzle vane position.

        A004M4YE02
        Text in Illustration
        *1 Turbocharger Sub-assembly *2 Linkage
        *3

        Actuator


        • DC Motor

        • Nozzle Vane Position Sensor

        		 *4 Compressor Wheel
        *5 Unison Ring *6 Nozzle Vane
        *7 Turbine Wheel *8 Drive Arm
        *9 Driven Arm - -

  2. OPERATION


    1. Turbocharger Sub-assembly


      1. General


        1. The exhaust gas from the exhaust manifold goes through the nozzle vane inside the turbocharger housing, and flows to the exhaust pipe through the turbine. The speed of the turbine (supercharging pressure) differs depending on the flow velocity of the exhaust gas going through the turbine and the flow velocity of the exhaust gas is controlled by the opening. Where there is less exhaust gas, such as during idling, the nozzle vane is almost fully closed. However, as there is a slight clearance between the vanes, the exhaust gas flows through the clearance to the exhaust pipe, and there is no bypass.

        A004M9BE02
        Text in Illustration
        *1 Nozzle Vane - -
        A004LTW Intake Air A004LMN Exhaust Gas

      2. At Low Load Range or Low Speed Range


        1. The actuator moves the linkage in the closing direction of the nozzle vanes in accordance with signals from the ECM.

        2. This results in increasing the velocity of the exhaust gas flowing to the turbine, as well as the speed of the turbine. As a result, torque is improved when the engine is running at low speeds.

        A004MC6E01
        Text in Illustration
        *1 Turbocharger Sub-assembly *2 Nozzle Vane
        *3 Unison Ring *4 Turbine Wheel
        *5 Drive Arm *6 Driven Arm
        *7 Linkage - -
        *a Exhaust Gas Flow - -

      3. At High Load Range or Medium-to-high Speed Range


        1. The actuator moves the linkage in the opening direction of the nozzle vanes in accordance with signals from the ECM. This opens the nozzle vane and holds the specified supercharging pressure, lowering the back pressure and improving the output and fuel consumption.

        A004MA2E01
        Text in Illustration
        *1 Turbocharger Sub-assembly *2 Nozzle Vane
        *3 Unison Ring *4 Turbine Wheel
        *5 Drive Arm *6 Driven Arm
        *7 Linkage - -
        *a Exhaust Gas Flow - -