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How the 2JZ sequential turbo system works
Old 11-20-2007, 11:35 AM   #1 (permalink)
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Default How the 2JZ sequential turbo system works

This thread is dedicated to the operation and diagnosis of the OEM Sequential Turbo system. Do not “quote” this thread since it will be too long and take up band width. I will be editing and changing this over the next week or so before it gets moved to an official thread position.

I highly recommend that people post there “fixes” so other people can see how certain situations were remedied. I will not have every possible “fix”

How the Sequential system works.

There are 5 main control components for a working sequential system. They are the Wastegate for overall boost control, Intake Control, Exhaust Control, Exhaust Bypass Control, and the Pressure Tank.

http://www.97supraturbo.com/Seq%20FA...m%20System.JPG

Within these 5 controls, 4 operate using VSV’s (vacuum switching valves) and actuators.

VSV’s These vacuum switches are controlled by the ECU, Based on inputs that the ECU gets, it determines when to open them. Once these are open, this allows pressure to go to the actuators. The 4 actuators (detailed below) all have different functions and all operate at different values (see chart above)
VSV’s http://www.97supraturbo.com/Supra%20...scriptions.pdf
Basic Testing : http://www.97supraturbo.com/Supra%20...stegateVSV.pdf
http://www.97supraturbo.com/Supra%20Scans/IACV.pdf
http://www.97supraturbo.com/Supra%20...EGCV%20VSV.pdf
http://www.97supraturbo.com/Supra%20Scans/EBV%20VSV.pdf

Quick testing overview for Wastegate Actuator, EGCV, IACV, and Axial Play on the turbos
http://www.97supraturbo.com/Supra%20...%20Testing.pdf



Actuators These are a diaphragm based mechanical plungers. As pressure is applied, it has an internal diaphragm that pushes against a rod. This rod then moves outward to open the valves. This pressure is from the opened VSV feeding the manifold pressure to it. Each actuator has different specifications as to when and how far it opens. So you can see if the VSV is bad, then these will not function. I have heard of these getting slight pinholes, but I really haven’t ever heard one go completely bad. Hence actuators would be one of the things I look at last in diagnosing.


1)Wastegate: This is for the overall control of Boost. The Wastegate uses an Actuator and a Vacuum Switching Valve (VSV). This VSV is controlled by the ECM system. The ECM takes in various data to determine the amount of Boost it provides. This is a “pulsating” VSV. or “modulated” to maintain a certain level of boost. (Opposed to “on”-“off”) OEM Boost is from 8.8 to 10.8 Psi.

http://www.97supraturbo.com/Seq%20FAQ/WG-EGCV%20VSV.JPG

2)Exhaust Bypass Valve (EBV): This controls the prespool of the #2 Turbo prior to full transition. It also has a VSV and Actuator that is controlled by the ECM. It is a linear acting actuator that starts to open at about 10.2 Psi and it is fully open around 14 Psi. As it opens, it starts the compressor blades spinning on the #2 turbo so by the time the actuator is fully opened the #2 has enough velocity to have a “smooth” transition at time of full boost. Typical boost characteristics will show peak psi at or around 10Psi starting 2200rpms to 2500rpms, holding there until 3300-3600rpms. Then a slight dip in boost just prior to full transition. After full transition (around3800 rpms}, the EBV system is non functional.

http://www.97supraturbo.com/Seq%20FAQ/EBV%20VSV.jpg
http://www.97supraturbo.com/Seq%20FA...20actuator.jpg

3)Intake Air Control Valve (IACV):

http://www.97supraturbo.com/Seq%20FA...tor%20IACV.jpg
http://www.97supraturbo.com/Seq%20FA...20Actuator.jpg

4)Exhaust Gas Control Valve (EGCV):

http://www.97supraturbo.com/Seq%20FA...tor%20EGCV.jpg
http://www.97supraturbo.com/Seq%20FAQ/EGCV-Arm.jpg

The above 2 Valves are the 2 main control systems for the full boosting of the Supra. Without both of these functioning properly, your car will NEVER see more than 10.8 Psi, even if you have the ability to go to 24psi. The EGCV basically closes off 50% of all exhaust energy, and the IACV closes off about 50% of the charged air. If either one valve isn’t functioning and does not open, then you will never see more than 10.8Psi. Other words, you’re running on the #1 turbo only from 1000-7000rpms if these don’t open.

Both these Valves open simultaneously at 3800 rpms. No sooner, and no later, There is NO other ECM input for this; RPM dependant only. What does vary is how long it takes for the transition. Duration of transition is somewhat related to the overall health of the sequential system. A faulty actuator damaged vacuum hose, faulty VSV, altitude and temperature are some of the leading factors. Going to temporary TTC will determine if there is a “turbo” problem or a Valve (VSV-Actuator) problem. This will be discussed later.

5)Pressure Tank: The Pressure tank is located underneath the Intake Manifold near the firewall. It has 2 connections. “A” pressure Input, and “B” pressure Output. The Pressure Input is from the front “Y” Pipe.
(Which also feeds the EBV Actuator)

http://www.97supraturbo.com/Seq%20FA...e%20Source.jpg
http://www.97supraturbo.com/Seq%20FA...r%20vacuum.jpg
http://www.97supraturbo.com/Seq%20FA...ure%20Tank.jpg

This pressure reserve is what opens both the EGCV and the IACV. If there are any defective parts in this area, then you will not see greater than 10.8spi. Going to Temp TTC using check valves will not function if the Pressure Tank system is faulty. As seen above, the pressure tank goes from rubber lines, then to metal, then back to rubber, then to metal (rear metal loom). This is a very difficult area for finding. bad components. You have to use a hand pump to pressurize the tank. If after pressurizing you do not get a release of air from pulling the IACV actuator hose, then there is a leak. Or the pressure tank is bad.
Another way is after driving the car, turn it off, open the hood, and pull off the IACV hose and listen for the release of air. If you do hear it, then the pressure tank is operating OK.


Overview of the Sequential System during LOW end use. http://www.97supraturbo.com/Seq%20FA...ke_exhaust.gif

Overview of Sequential System during Pre-spool: http://www.97supraturbo.com/Seq%20FA...ke_exhaust.gif
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Old 11-20-2007, 11:35 AM   #2 (permalink)
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Overview of Sequential System at Full transition: http://www.97supraturbo.com/Seq%20FA...ke_exhaust.gif


So those are the control systems. There is a great webpage called Max Boost by John A. That goes into greater detail of the full operation of the Sequential System. This will explain the whole orchestration from idle to redline. (Thanks John)

http://www.max-boost.co.uk/max-boost/supra/turbo.htm




Various ways in Performing True Twin Conversion (TTC):

Temp TTC with Check Valves. This allows the pressurized air from the pressure tank to “hold” open the EGCV and IACV by not allowing the air to escape. One way check valves allows air to pass in 1 direction. The pressure tank MUST be in good working order for this to work. Perform this in order to determine if the symptoms are turbo related or plumbing related. If you get greater than 10.8psi by doing this (or full boost) then the problem is NOT #2 Turbo related.

Install 2 check valves, 1 on the IACV actuator nipple, and the other on the EGCV nipple. Make sure that the orange stripe is facing toward the front of the car.

http://www.97supraturbo.com/Seq%20FA...0for%20TTC.JPG
http://www.97supraturbo.com/Seq%20FA...ck%20Valve.jpg
http://www.97supraturbo.com/Seq%20FA...ck%20Valve.jpg
This a very nice write up from the Australian forums:
http://mkiv.supras.org.nz/articles/andy.htm


I have heard of people doing what is called a “ghetto” TTC. I am not sure what this is exactly, but my assumption is that it is a quick a temporary way. Maybe this will be explained.

Also, a complete installation of the TTC with check valves can be found in www.MKiV.com under the Tech Articles.

Another way, which isn’t as easy to undo, is taking small gauge wire and actually tying them up. I will try to find a link.

Lastly, which is what I use, is the ETTC way. This requires wiring up a DPST switch that is connected to the ECU IACV and EGCV circuits. It “grounds” out the signal to the 2 VSV’s and permanently keeps them open. So in effect, it’s like they are not even there. Downside to this is that you need to always flip the switch off prior to turning the car off or it will cause a CEL (check engine) Good mod for people who track there car. Much easier on the #2 turbo, and much smoother.

http://www.97supraturbo.com/Seq%20FAQ/ETTC%20Mod.JPG


Boost related symptoms’ and possible cures.

As mentioned above briefly, one of the most common complaints is having low to no boost through out the rev range. There can be several possibilities. The first thing anyone should do after the basic visual on
loose hoses, is to do the temp TTC. It is REALLY easy to replace about $10 worth of vacuum hoses in about 4 or 5 places that are critical to the successful operation of transition. (see diagram above on where these IAVC and EGCV hoses connect.

This will rule out many other possibilities by doing this. It will rule out:
1) bad #2 turbo,
2) Bad or defective pressure tank,
3) Broken off EGCV ceramic flapper,
4) Collapsed rubber turbo pipe coupler,
5) Defective reed valve.

If the car runs great in Temp TTC, then you need to start looking at items OTHER than the 4 above. Like;

1) IACV hoses.
2) EGCV hoses.
3) IACV and EGCV VSV’s (Check continuity and 12v test) http://www.97supraturbo.com/Supra%20Scans/IACV.pdf
http://www.97supraturbo.com/Supra%20...EGCV%20VSV.pdf
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Old 11-20-2007, 11:35 AM   #3 (permalink)
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Now, If the car still runs like crap, then it can be one of the 4 items above.

1) Requires the removal of a lot of stuff to inspect the compressor blades. So let’s save that for last!
2) As also mentioned above, the really easy way to test is to pull the hose off the IACV after driving the car. I have actually had a release of air several hours after the car has been off. So it does hold air
very well. If not, look for a bad hose from the rear loom to the Pressure tank. Or check the pressure tank itself by reaching up from below and see if you can feel both hoses attached.
3) You can check this by either removing the DP or doing a visual, or by unbolting the 3 bolts that hold the EGCV to the turbo assembly. You will know if it has snapped off. You may even be able to see it if you wiggle the lever. Broken flapper arm is not that uncommon.
4) More rare, but I read about someone who went single because his turbos took a dump (he thought) and it turned out to be a collapsed inner wall. This is a common symptom, but not that common to collapse all the way closed. http://www.97supraturbo.com/Seq%20FAQ/Corrugated.jpg
5) The IACV has a reed valve inside it. The reed valve is more for preventing back pressure. But there is a
valve in there, similar to the EGCV valve, and it has been know to to get loose (although the screws were “locktited” from the factory. If they get loose enough, it can “bind up” and not open. This is can be easy to see by removing the IACV actuator rod and just move the arm.
http://www.97supraturbo.com/Seq%20FA...ed%20Valve.jpg

Now, to elaborate more on the #2 taking a dump. Obvious death wine, smoke bellowing out the rear, metal on metal sound being reverberated through the heat shield, and a definite moaning sound. Another good reason on the temp TTC is because you can actually run the car at idle, and if the 2 actuators are open, it allows exhaust pressure to flow to the #2 turbine and spin up the #2. You will definitely hear a bad #2 in this case. Then you wouldn’t need to rev the car past 3800 to activate the #2. What can also happen is a bent or busted shaft. That is usually caused by a defective EBV. If the EBV has a defect, or a hose that has cracked or come off, it will never allow for any pre-spool. This means that at 3800 rpms when both the IACV and EGCV open, it is like opening the flood gates and all of the exhaust energy is thrown at the #2. Kind of think of it as a relay race with the handing off of the baton. If the #2 is just sitting there idle, and it gets blasted, it will most definitely get bent of bust. Not maybe right away, but if this continues to happen, it’s a matter of time.

A good tool for testing all of the actuators is a MityVac:

http://www.97supraturbo.com/Seq%20FAQ/MityVac.jpg. About $50. Has a gauge and can do pressure as well as vacuum.

Here is a link to a pressure testing system that a member posted awhile back. This is another way to check for leaks and lower turbo hoses. http://www.supraforums.com/forum/showthread.php?t=78644

Other issues regarding boost.

A typical healthy OEM Supra will not feel the transition as prominent as someone who has a boost controller and fuel cut defender (BCC). Since the OEM boost characteristic is 8.8 psi to 10.8 psi, and the EBV holds it at about 10.2 psi, the transition isn’t that abrupt. If the EBV system is working properly, then there will be a dip in boost pressure of about 1-2psi. prior to 3800 rpms. The symptom of getting
near “0” psi at transition is an EBV related issue. The problem of have boost falling off as the rpms are increased is a Wastegate issue. Wastegates are notorious for taking a dump with the Supra. They crap out a lot. It could be a slight hole or crack in a vacuum hose. As the pressure rises, it opens, and releases the pressure that is needed to hold the wastegate actuator open. On the flip side, there are the ones who get too much boost. A good possibility is a cracked wastegate hose cap. It can be near impossible to see it. When you install an EBC, you need to put a small cap over the front facing actuator nipple and tie it off. It gets prone to heat and can actually pop off the tip enough so it “flaps” as the pressure rises. This causes “no” control of boost, or unlimited, because it can’t pressurize itself and hold open the wastegate.

Now, lets look a some actual scenarios and the possible fixes.

Here is an actual diagnose and fix from a member.

Symptoms: #2 Does not come online, boost falls off after 4.2k rpm.

Description of Unsuccessful Tests: No pressure release from VSV hoses after hitting .7bar 5 times and immediately stopping to pull VSV hoses to check for pressure release. After alot of testing, the IAC and EGC actuators/VSV's checked out perfectly. After a boost leak test, tiny amounts of air were found to be escaping from the IAC VSV connections, which caused a tiny amount of boost fluctuation. 2 zip ties were put on every vacuum connection coming from the pressure tank outlet line. VSV bypass TTC and ETTC did not do anything. Each actuator would hold pressure perfectly. the entire system seemed to be in perfect condition.

Successful Diagnosis Test: I decided to pressure test the post pressure tank line and components via the wire loom nipple that feeds to the IAC VSV. Pressure escaped from the y-pipe line, which was unplugged from the barb. Immediately realized the pressure tank was failing or the inlet outlet lines were switched. Visual inspection of the p. tank inlet connection revealed that the rubber vacuum line was partially blown off due to pressure build up.

Fix: Swap the pressure tank inlet and outlet lines, which a mechanic had switched during turbo assembly reinstallation. The lines can be swapped at the pressure tank without removing anything if you have small enough hands, which I do not. A guy at my mechanics garage happened to have some tiny hands and was able to swap the lines


By: Stu Hagen http://www.97supraturbo.com
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