Turbocharger Noise [10/2015 - ]: Procedure

1. Confirm with the customer the condition when noise occurred.

   HINT: 

   To clearly understand the conditions in which the noise occurred, the items in the table below are useful.

   Item	Note
   Engine speed	Engine speed range
   Vehicle speed	Vehicle speed range
   Transmission gear	Which gear?
   Accelerator pedal position	During acceleration or deceleration?
   Temperature	Ambient temperature Engine temperature (cold, warmed up, etc.)
   Road conditions	City or highway driving Uphill or downhill
   Noise level	Did the noise occur suddenly, or build gradually? Has the noise gradually been getting louder?
   Other symptoms	Lack of power High fuel consumption, etc.
   Noise recognition	What made the customer determine that the sound was a malfunction?

   Result

   Proceed to

   NEXT

Result: 

NEXT 

See step  2

1. Connect the Techstream to the DLC3.
2. Turn the engine switch on (IG).
3. Turn the Techstream on.
4. Enter the following menus: Powertrain / Engine / Trouble Codes.
5. Check the DTCs.

   Powertrain > Engine > Trouble Codes 

   Result

   Result	Proceed to
   DTCs are not output	A
   DTCs are output	B

   HINT: 

   • Check whether DTCs related to the boost pressure sensor or atmospheric pressure sensor are output.
   • If a DTC related to the boost pressure sensor or atmospheric pressure sensor is output, defective actuator control related to the turbocharger may be the cause of the noise.

Result: 

B 

GO TO DTC CHART. Refer to  DIAGNOSTIC TROUBLE CODE CHART [10/2015 - 08/2016]  , or refer to  DIAGNOSTIC TROUBLE CODE CHART [08/2016 - 11/2017]  , or refer to  DIAGNOSTIC TROUBLE CODE CHART [11/2017 - 10/2018]  , or refer to  DIAGNOSTIC TROUBLE CODE CHART [10/2018 - 11/2019]  , or refer to  DIAGNOSTIC TROUBLE CODE CHART [11/2019 - 09/2020]  , or refer to  DIAGNOSTIC TROUBLE CODE CHART [09/2020 - 10/2022]  , or refer to  DIAGNOSTIC TROUBLE CODE CHART [10/2022 - ] 

Result: 

A 

See step  3

1. Check whether the noise described by the customer occurs.

   HINT: 

   If an abnormal noise is heard, check whether it matches the noise described by the customer.

2. If an abnormal noise is confirmed, determine which system emits it.

   Result

   Result	Proceed to
   Noise occurs (ticking or rattling (metallic sound) during idling)	A
   Noise occurs (squealing (metallic sound) when driving)	B
   Noise occurs (hissing (airflow sound) when driving)	C
   Noise occurs (squeaking or chuffing (airflow sound) during deceleration)	D
   Noise occurs (whistling or foghorn-like (airflow sound) during acceleration)	E
   Noise occurs (whistling (airflow sound) during deceleration)	F
   The noise described by the customer could not be confirmed	G

Result: 

B 

See step  6

Result: 

C 

See step  12

Result: 

D 

See step  20

Result: 

E 

See step  23

Result: 

F 

See step  28

Result: 

G 

See step  29

Result: 

A 

See step  4

1. Check the installation condition of the E-ring on the link connection of the waste gate valve actuator with bracket assembly and turbine housing with valve sub-assembly.

   HINT: 

   Replace the E-ring if the installation condition is abnormal.

2. When the actuator rod of the waste gate valve actuator with bracket assembly is pushed down, check whether there is a change in the abnormal noise.

   HINT: 

   If there is a change in abnormal noise when the actuator rod is pushed down, the noise may be a metallic sound from increased rattle due to wear.

   Result

   Result	Proceed to
   There is no change in the abnormal noise when the actuator rod is pushed down.	A
   There is a change in the abnormal noise when the actuator rod is pushed down.	B

Result: 

B 

REPLACE WASTE GATE VALVE ACTUATOR WITH BRACKET ASSEMBLY. Refer to  REMOVAL [10/2015 - ] 

Result: 

A 

See step  5

1. Check for damage to the compressor impeller.
2. Check for interference between the compressor impeller and the compressor housing.

   Result

   Result	Proceed to
   No damage or interference	A
   Damage or interference exists	B

Result: 

A 

END (CAUSE CHECK EXCEPT THE TURBO CHARGER) 

Result: 

B 

REPLACE COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY. Refer to  REMOVAL [10/2015 - ] 

1. Check that the turbine shaft rotates smoothly, without catching.

   Refer to ON-VEHICLE INSPECTION [10/2015 - ]

2. Check for loose turbine mounting nuts and for axial play in the turbine shaft.

   Refer to INSPECTION [10/2015 - ]

   HINT: 

   If the turbine shaft catches or if there no play or excessive play, it could indicate poor sliding due to seal damage due to seizing or a deposit build-up.

   Standard value

   0.10 mm (0.00394 in.) or less

   Result

   Result	Proceed to
   No turbine shaft malfunction	A
   Turbine shaft malfunction	B

Result: 

B 

REPLACE COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY. Refer to  REMOVAL [10/2015 - ] 

Result: 

A 

See step  7

1. Check for damage to the compressor impeller.
2. Check for interference between the compressor impeller and the compressor housing.

   Result

   Result	Proceed to
   No damage or interference	A
   Damage or interference exists	B

Result: 

B 

See step  11

Result: 

A 

See step  8

1. Inspect the air by-pass valve assembly, referring to On-vehicle Inspection for Air by-pass Valve Assembly.

   Refer to ON-VEHICLE INSPECTION [10/2015 - ]

2. Inspect the air by-pass valve assembly, referring to Inspection for Air by-pass Valve Assembly.

   Refer to INSPECTION [10/2015 - ]

   HINT: 

   • The abnormal noise may be caused by defective operation of the air by-pass valve assembly.
   • If the previous checks find no malfunction, replace the compressor housing with bearing sub-assembly and determine if the noise improved.

   Result

   Proceed to
   OK
   NG

Result: 

NG 

REPLACE AIR BY-PASS VALVE ASSEMBLY. Refer to  REMOVAL [10/2015 - ] 

Result: 

OK 

See step  9

1. Replace the compressor housing with bearing sub-assembly.

   Refer to REMOVAL [10/2015 - ]

   Result

   Proceed to
   NEXT

Result: 

NEXT 

See step  10

1. Check that the abnormal noise has disappeared.

   Result

   Proceed to
   NEXT

Result: 

NEXT 

END 

1. Check for interference between the turbine wheel and the turbine housing.

   HINT: 

   If interference exists between the turbine wheel and turbine housing, replace the compressor housing with bearing sub-assembly and turbine housing with valve sub-assembly as a set.

   Result

   Result	Proceed to
   No damage or interference	A
   Damage or interference exists	B

Result: 

A 

REPLACE COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY. Refer to  REMOVAL [10/2015 - ] 

Result: 

B 

REPLACE COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY AND TURBINE HOUSING WITH VALVE SUB-ASSEMBLY. Refer to  REMOVAL [10/2015 - ] 

1. Check that no soot or oil adheres to the turbocharger sub-assembly connectors.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT: 

   If adhering soot or an oil leak exists, air leaking at that position may be the cause of the abnormal noise.

   Result

   Result	Proceed to
   No adhering soot or an oil	A
   Soot adhering around the turbine housing, flange, or V band (A in the illustration)	B
   Oil leak from the contact surface between the compressor housing and the seal plate or between the seal plate and the bearing housing (B in the illustration)	C
   Oil adhering to the compressor flange (C in the illustration)	D

Result: 

B 

See step  17

Result: 

C 

REPLACE COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY. Refer to  REMOVAL [10/2015 - ] 

Result: 

D 

REPLACE GASKET 

Result: 

A 

See step  13

1. Check if the waste gate valve actuator with bracket assembly operates normally when a negative pressure is applied to it.

   Refer to INSPECTION [10/2015 - ]

   HINT: 

   If the negative pressure leaks and the actuator rod is not maintained when negative pressure is applied to the waste gate valve actuator with bracket assembly, there may be an air leak due to a tear in the actuator diaphragm.

   Result

   Proceed to
   OK
   NG

Result: 

NG 

REPLACE WASTE GATE VALVE ACTUATOR WITH BRACKET ASSEMBLY. Refer to  REMOVAL [10/2015 - ] 

Result: 

OK 

See step  14

1. Check for wear or deformation of the air by-pass valve assembly contact surface.

   HINT: 

   • Wear or deformation on the air by-pass valve assembly contact surface may allow air to leak from the damaged position.
   • If the previous checks find no malfunction, replace the compressor housing with bearing sub-assembly and determine if the noise improved.

   Standard

   Wear or deformation does not exceed 0.50 mm (0.0197 in.)

   Result

   Proceed to
   OK
   NG

Result: 

NG 

REPLACE AIR BY-PASS VALVE ASSEMBLY. Refer to  REMOVAL [10/2015 - ] 

Result: 

OK 

See step  15

1. Replace the compressor housing with bearing sub-assembly.

   Refer to REMOVAL [10/2015 - ]

   Result

   Proceed to
   NEXT

Result: 

NEXT 

See step  16

1. Check that the abnormal noise has disappeared.

   Result

   Proceed to
   NEXT

Result: 

NEXT 

END 

1. Check for deformation or cracks in the mounting surfaces on the exhaust manifold converter sub-assembly and the turbine housing with valve sub-assembly.

   HINT: 

   Deformation or cracks on a mounting surface may allow exhaust gas to leak from the damaged position.

   Standard

   No deformation or cracks on a mounting surface

   Result

   Result	Proceed to
   No problem with the mounting surface	A
   Deformation or cracks on the exhaust manifold converter sub-assembly mounting surface	B
   Deformation or cracks on the turbine housing with valve sub-assembly mounting surface	C

Result: 

B 

REPLACE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY. Refer to  REMOVAL [10/2015 - ] 

Result: 

C 

REPLACE TURBINE HOUSING WITH VALVE SUB-ASSEMBLY. Refer to  REMOVAL [10/2015 - ] 

Result: 

A 

See step  18

1. Replace the exhaust pipe clamp and the gasket.

   Result

   Proceed to
   NEXT

Result: 

NEXT 

See step  19

1. Check that the abnormal noise has disappeared.

   Result

   Proceed to
   NEXT

Result: 

NEXT 

END 

1. Inspect the air by-pass valve assembly, referring to On-vehicle Inspection for Air by-pass Valve Assembly.

   Refer to ON-VEHICLE INSPECTION [10/2015 - ]

2. Inspect the air by-pass valve assembly, referring to Inspection for Air by-pass Valve Assembly.

   Refer to INSPECTION [10/2015 - ]

   HINT: 

   The abnormal noise may be caused by defective operation of the air by-pass valve assembly.

   Result

   Proceed to
   OK
   NG

Result: 

NG 

REPLACE AIR BY-PASS VALVE ASSEMBLY. Refer to  REMOVAL [10/2015 - ] 

Result: 

OK 

See step  21

1. Connect the Techstream to the DLC3.
2. Turn the engine switch on (IG).
3. Turn the Techstream on.
4. Enter the following menus: Powertrain / Engine / Data List / Atmospheric Pressure.

   Powertrain > Engine > Data List 

   Tester Display
   Atmospheric Pressure

5. Using the following table, determine the normal atmospheric pressure for the current altitude and temperature.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT: 

   • Standard atmospheric pressure is approximately 101 kPa (abs) (14.65 psi (abs)).
   • For every 100 m (328 ft.) increase in altitude, atmospheric pressure drops by approximately 1 kPa (0.15 psi). This varies depending on the weather.
6. Compare the value of Atmospheric Pressure with the normal atmospheric pressure in the table.

   Result

   Result	Proceed to
   Other than below	A
   Difference between value of Atmospheric Pressure and normal atmospheric pressure is 10 kPa (1.45 psi) or higher	B

Result: 

B 

REPLACE ECM. Refer to  REMOVAL [10/2015 - ] 

Result: 

A 

See step  22

1. Inspect the No. 2 turbo pressure sensor.

   Refer to PROCEDURE - Step 1

   Result

   Proceed to
   OK
   NG

Result: 

OK 

REPLACE ECM. Refer to  REMOVAL [10/2015 - ] 

Result: 

NG 

REPLACE NO. 2 TURBO PRESSURE SENSOR. Refer to  PROCEDURE - Step 2 

1. Check that the turbine shaft rotates smoothly, without catching.

   Refer to ON-VEHICLE INSPECTION [10/2015 - ]

2. Check for loose turbine mounting nuts and for axial play in the turbine shaft.

   Refer to INSPECTION [10/2015 - ]

   HINT: 

   If the turbine shaft catches or if there no play or excessive play, it could indicate poor sliding due to seal damage due to seizing or a deposit build-up.

   Standard value

   0.10 mm (0.00394 in.) or less

   Result

   Result	Proceed to
   No turbine shaft malfunction	A
   Turbine shaft malfunction	B

Result: 

B 

REPLACE COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY. Refer to  REMOVAL [10/2015 - ] 

Result: 

A 

See step  24

1. Check for damage to the compressor impeller.
2. Check for interference between the compressor impeller and the compressor housing.

   HINT: 

   If the previous checks find no malfunction, replace the compressor housing with bearing sub-assembly and determine if the noise improved.

   Result

   Result	Proceed to
   No damage or interference	A
   Damage or interference exists	B

Result: 

B 

See step  27

Result: 

A 

See step  25

1. Replace the compressor housing with bearing sub-assembly.

   Refer to REMOVAL [10/2015 - ]

   Result

   Proceed to
   NEXT

Result: 

NEXT 

See step  26

1. Check that the abnormal noise has disappeared.

   Result

   Proceed to
   NEXT

Result: 

NEXT 

END 

1. Check for interference between the turbine wheel and the turbine housing.

   HINT: 

   If interference exists between the turbine wheel and turbine housing, replace the compressor housing with bearing sub-assembly and turbine housing with valve sub-assembly as a set.

   Result

   Result	Proceed to
   No damage or interference	A
   Damage or interference exists	B

Result: 

A 

REPLACE COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY. Refer to  REMOVAL [10/2015 - ] 

Result: 

B 

REPLACE COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY AND TURBINE HOUSING WITH VALVE SUB-ASSEMBLY. Refer to  REMOVAL [10/2015 - ] 

1. Check if gear noise is the source of the abnormal noise (not noise from the turbocharger).

   Result

   Proceed to
   NEXT

Result: 

NEXT 

ELIMINATE THE CAUSE OF THE NOISE 

1. Explain to the customer that the sound described by the customer is not a malfunction.

   HINT: 

   To convince the customer, it is helpful to drive the customer in a different vehicle.

   Result

   Proceed to
   NEXT

Result: 

NEXT 

END