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MITSI,JBISHI
H$$Its THE COLTCAR COMPANY
DATE 22 Julv2005 Revised{€010212007\
NUMBER sNL-2005-15-002
MODEL L200(P),ShoqunSport(P45)
GROUP IntakeAnd Exhaust(15)
SUBJECT VG Turbo(4D56)
SettinqUp/Optimisinq
TYPE ServiceNewsletter

Condition:
Theenginemanagement systemusedon the4D56engineis designed to protectthe engine
andfor this reasonlimitsthe engine power outputin the eventof an over-boostsituation.
Therefore, whenthe ECUdeterminesan over-boost situation,it will limitthe amountof fuel
injectedby the injectionpumpin orderto reducethe exhaustgas energy.The customermay
recognise this as a lackof poweror a typeof enginehesitation.

The4D56VariableGeometryturbocharger outputis very sensitiveand thereforeneedsto be

setupwithinthe tolerancesprovidedby MMC. Althoughwe havepreviouslypublished
adjustmentproceduresin Newsletter SNL-2003-15-004 we haverevisedthe setupprocedure to
shouldbe carriedout. Thisadjustmentprocedure
ensurethat it is clearhow the adjustments
needsto be carriedout in orderto avoidthe unnecessary replacement of turbochargerunits.

Although published,
are similarto whatwe havepreviously
the detailsin thisnewsletter please
ensurethat you readthis newsletter
thoroughly as thereare somevery importantrevisions.

Setup Procedure:
Step1
1) Thereare two differenttypesof stopperboltusedon the turboassemblies(seebelow
picture),thereare alsotwo differentspecifications
dependingon the typefitted. Therefore,
beforechecking/carrying out the adjustmentprocedure,it is necessaryto checkthe shapeof
the stopperboltsto determinewhichone is fitted.

A; Run-outof thread B: Completetluead

2) Countthe numberof threadsfor the stopperbolts('C and D portions'in the belowpicture)

andthe turnbuckle('E and F portionsin the belowpicture).

Note: Do not countthe threadnumberof the run-outthreadportion.

Note: lf you haveanyquestionsregardingthis Nelvsletter,

pleasesubmita TechnicalServiceRequest(TSR)to the TechnicalServiceDepartment.

@2005TheColtCarCompanyLtd. Page1 of 7
 Fig 2: Locationof the checkingpoints and paint mark location

3) Basedon the resultsof step2, carryout the following:

. arewithinthe specification,
lf the numberof threadson the stopperboltsandturnbuckle
it is not necessaryto re-adjustanything.

o lf the numberof threadson the stopperboltsand/orturnbuckleare not withinthe

it is necessaryto re-adjustthem. Therefore,adjustthem as perthe
specification,
'recommended (whichis an averageof the factoryspecification)
specification' in the
tablebelow. Ncte:Whenadjustingthe turnbuckle, do not applystressto the actuator
rod.

F c2 tion of number of threads

Type of PortionC PortionD PortionE F
Portion
stopperbolt (Stopperfor full open) (Stopperforfull (Turnbuckle) (Turnbuckle)
close)
A: Run-outof 0-2 Ridges 8-10Ridges
thread 2-3 Ridges
2-4 Ridges
B. Complete 2-4 Ridges 10-12Ridges
Thread

Recommended of numberof threads:

Typeof PortionC PortionD PortionE F
Portion
stopperbolt (Stopperfor full open) (Stopperfor full (Turnbuckle) (Turnbuckle)
close)
A: Run-outof 1 Ridge 9 Ridges
thread 2 . 5R i d g e s
3 Ridges
B: Complete 3 Ridges 11Ridges
Thread

pleasecheckthe locknutsare tighteningcorrectly.

4) Aftermakingadjustments,

pleasesubmita TechnicalServiceRequest(TSR)to the TechnicalServiceDepartment.

Note: lf you haveanyquestionsregardingthis Newsletter,

O2oosThecoltCarCompanyLtd. Page2of7
 Step2
Carryoutthe followingbasicchecksfor generalmovementand functioning
of the VGT system
mustbe carriedout.

1) Mechanicalcondition check(withcoldengine):
. Unclipthe circlipthat securesthe actuatorrodto the VGT lever
. Removethe actuatorrodfromthe VGT lever
. Checkthejointfor corrosionand for smoothoperationwiththe actuatorrod
. Checkfor smoothoperationof the actuatorrod intothe actuator
. Checkfor smoothoperationof the VGT leverfrom MAXto MIN position(somefree play
on the axleis allowed)
. Re-installtheactuatorrodto the VGT leverand re-fitthe circlip

2) Mechanicalcondition check(withhotengine):
. Runthe engineup to normaloperating temperature
. Switchthe engineoff
. Unclipthe circlipthat securesthe actuatorrod to the VGT lever
. Checkfor smoothoperationof the VGT leverfrom MAXto MIN position(somefree play
on the axleis allowed)
. Re-installthe actuatorrodto the VGT leverand re-fitthe circlip

Caution:Pleaseensurethatprecautions suchas heatproofgloves,etc.aretakenwhen

to preventburns.
workingon a hot engine/turbo

3) DynamiccheckusingMUT-lll:
. Setthe vehicleup for datarecording itemsfromthe datalist:
usingat leastthe following
- Enginerpm
- Roadspeed
- Boostpressure
. TPS
- Boostactuatorpressure
. Roadtestthe vehicleand checkfor maximumboost. Whencarryingout the roadtest,it
is important
to drivethe vehicleto obtainmaximumboost,as opposedto maximum
enginespeed,thereforecheckfor maximumboostduringfullthrottleacceleration in 4th
gearfrom1500rpm upwards(ensuring speedlimits,etc.are adheredto). lt is also
necessaryto ensurethat any powerupgradefittedis disconnected whilstcarryingout
the roadtest.

Note: lf you haveanyquestionsregardingthis Newsletter,

pleasesubmita TechnicalServiceRequest(TSR)to the TechnicalServiceDepartment

@2005TheColtCarCompanyLtd, Page3 of 7
 Fullboostabove2500 rpmshouldbe between180- 200 kPa (constantboost). lf full
boostis greaterthan 200KPafor longerthan5 secondsor if it staysbelow180 kPa,
pleasecarryout the restof the stepsin this Newsletter

Notes:
. Withthe ignitionoff,the VGT levershouldtouchthe lowerstopperbolt
. Whenidling,the levershouldalmosttouchthe upperstopperbolt
. Whenquicklyrewing the enginein neutral,the VGT levershouldalmosttouchthe lower
stopperbolt
. Dueto the way the turbosystemoperates,it is normalto see a peakin boostpressure
whenchangesare madeto the throttleposition(suchas changinggear,or increasing
the throttle).A peakin the boostpressureis acceptable
for a shortperiodtime
(approximately 5 seconds)and thereforethe engineECUwill not see this as a fault.
Afterthis peakin the boostpressure,the boostpressureshouldstabiliseat a constant
value.

prrHboorl$horttimc,nomElc0ntol

Step3 (lf FullBoostls GreaterThan200KPa)

lf full boostexceeds200KPafor greaterthan5 seconds,this can be causedby the VGT lever
travelnot beinggreatenoughdue to:

r adjustedlowerstopperbolt(A)
An incorrectly
. The actuatorrod is adjustedtoo short(B)

A) Pleasebe awarethat it is the lower stopperboltthat controlsmaximumboost. Whenthe

VGT levermovestowards/isagainstthe lowerstopperbolt(positionshownin belowphoto),this
reducesturbospeed/boost pressure,similarto openingthe wastegateon a conventional turbo.
Therefore,if the lowerstopperboltis incorrectly adjusted(screwedtoo far in),thiswill prevent
the VGT leverfrom movingfar enoughand thereforewill not allowthe vanesto moveenoughto
be ableto slowthe turbodownenough.Thiswill resultin too muchboost(pleaseseethe
generalinformation and alsothe attachedvideoclip(in the
at the end of this Newsletter
attachments tab, selectthe attachment. Thenclickopen)to see the relationshipbetweenvane
position,turbospeedand turboboost).

Note: lf you haveanyquestionsregardingthis Newsletter,

pleasesubmita TechnicalServiceRequest(TSR)to the TechnicalServiceDepartment.

@2005TheColtCarCompanyLtd. Page4 of 7
 lf the lowerstopperboltis screwedin too far,fineadjustments
to the lowerstopperboltwill
needto be madeby adjustingit halfa turnanti-clockwise stepby stepuntilthe maximumboost
pressureis between180- 200 KPa (above2500rpm at fullthrottle,as mentionedpreviously in
the 'Dynamic CheckWithMUT-lll'section).Thetargetboostpressure shouldbe 180KPa.

Pleasebe awarethatthe lowerstopperboltshouldneverbe screwedall the way out,othenarise

the vaneswill makecontactwiththe turbine.

Thefinaladjustment
shouldnot exceedthe factoryspecification
of numberof threadsas shown
on page2.

B) lf the VGT leveris not touchingthe lowerstopperboltthis may be causeddue to the length
of the VGT actuatorrod beingtoo short. To set up the actuatorrod,withthe actuatorrod
disconnected, pushthe VGT leveracrossso that it is pushedup againstthe lowerstopperbolt.
Thenadjustthe actuatorrod so thatthereis a veryslightpre-loading pushingthe VGT leverup
againstthe lowerstopperbolt.

Step4 (lf FullBoostls LessThan 180KPa/Poor ThrottleResponseAt Low RPM)

lf fullbooststaysbelow180kPaorthereis poorthrottle response
at low rpm,thiscanbe
causedby the VGT levertravelnot beinggreatenoughdue to:

. Upperstopperbolt not adjustedcorrectly(A)

. Actuatorrod not adjustedcorrecfly(B)

A) The upperstopperboltdeterminesinitialboost. Whenthe VGT levermovestowards/is

againstthe upperstopperbolt,this increasesturbospeed/boost pressure(obviously depending
on enginespeed/loadas well),similarto closingthe wastegateon a conventional turbo.
Therefore,if the upperstopperboltis incorrectly
adjusted(screwedtoo far in),thiswill prevent
the VGT leverfrom movingfar enoughand thereforewill not allowthe vanesto moveenoughto
be ableto spintheturboup fastenough.Thiswillresultin slowbuiltup of boostpressure anda
reducedamountof boostpressure(pleasesee the generalinformation at the end of this
Newsletter and alsothe attachedvideoclip(in the attachmentstab,selectthe attachment. Then
clickopen)to see the relationship
betweenvane position,turbospeedand turboboost).

lf the upperstopperboltis screwedin too far,fineadjustments

to the upperstopperboltwill
needto be madeby adjustingit halfa turn anti-clockwisestepby stepand checkif normal
responseat low rpm is achieved.

Pleasebe awarethatthe upperstopperboltshouldneverbe screwedall the way out,othenvise

the vaneswill totallyclose. lt is possibleto checkfor the maximum'woundout' positionof the

Note: lf you haveanyquestionsregardingthis Ne\/sletter,pleasesubmita TechnicalServiceRequest(TSR)to the TechnicalServiceDepartment.

@2005TheColtCar CompanyLld. Page5 of 7

 upperstopperboltby windingthe top stopperboltout,thenwiththe actuatorrod disconnected
pushthe VGT leveracrosstowardsthe upperstopperbolt. Thenwindthe upperstopperbolt
inwardsuntilit just touchesthe VGT lever,thenscrewit in a quarterof a turn.

Thefinaladjustment
shouldnot exceedthe factoryspecification
of numberof threadsas shown
on page2.

B) lf the VGT leverdoes not touchthe upperstopperboltduringfull boost,this may be caused

due to the lengthof the VGT actuatorrod beingtoo long. To set up the actuatorrod,withthe
actuatorrod disconnected, pushthe VGT leveracrossso that it is pushedup againstthe lower
stopperbolt. Thenadjustthe actuatorrod so thatthereis a very slightpre-loading pushingthe
VGT leverup againstthe lowerstopperbolt.

Generallnformation:
Foryourinformation, we haveincludedthe belowdiagramsto showthe positionsof the vanes
to the positionof the VGT lever/actuator.
in relationship Thereis alsoa videoclipattachedto
this Newsletter,
whichshowsthe relationship betweenturbovane position,turbospeedand
turboboost.

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Turbo ReplacementProcedure:
lf you feelthat a newturbois requiredon the vehiclebecausethe turbohas beenset up
correctlyand the vehicleis stillover-boosting,
it is essentialthatthe followingis carriedout
beforethe turbois replaced:

1. Submita TechnicalServiceRequest(TSR)to the TechnicalDepartment givingthe exact

symptomsand whatdiagnoseshas beencarriedout. lf the turbois a DMXturbo,you
will alsoneedto includethe test numberoff the actuator.
2. Whenthe TSR is submitted,it is alsoessentialthat data recordings
containingall the
relevant data(includingenginerpm,roadspeed,boostpressure, TPS and boost
actuatorpressure)is attachedto the TSR. Whencarryingout the data recordings, it is
importantto drivethe vehicleto obtainmaximumboost,as opposedto maximumengine

Note: lf you haveanyquestionsregardingthis Neualefter,pleasesubmita TechnicalServiceRequest(TSR)to the TechnicalServiceDepartment.

@2005TheColtCarCompanvLtd. Page6 of 7
 speedas mentionedearlierin this Newsletter.lt is also necessaryto ensurethat any
powerupgradefitted is disconnectedwhilstcarryingout the roadtest.
3. lf aftersubmittingthe TSR,if it is agreedthatthe turboneedsto be replaced,the TSR
numberwill needto be mentionedin the warrantyclaimin orderfor the claimto be paid.

Note: lf the aboveprocedureis not carriedout,our WarrantyDepartment will not authorisethe

warrantyclaim. lt is alsoessentialthat if the turbois replaced,that it is correctlylabelledwhen it
is returned(as per ServiceBulletinNo 1338).

WarrantyReimbursement:
Position
Code - 155010
A-Code - 49
B-Code - 04
C-Code - G
Operation Code - 15501099
Operation Time - O.2HrsA/ehicle

Note: lf you haveanyquestionsregardingthis Ne\Elefter,pleasesubmita TechnicalServiceRequest(TSR)to the TechnicalSeMceDepartment

@20O5The0oltCarCompanyLld. PageTol 7