Turbocharger Noise [09/2022 - ]: 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. Check the DTCs.

   Powertrain > Engine > Trouble Codes 

   Result

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

   HINT: 

   • Check whether a DTC is stored related to the boost pressure sensor or atmospheric pressure sensor (in ECU).
   • If a DTC is stored related to the boost pressure sensor or atmospheric pressure sensor (in ECU), defective actuator control related to the turbocharger may be the cause of the turbocharger noise.

Result: 

B 

GO TO DTC CHART 

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 (whistling or foghorn-like (airflow sound) during acceleration or deceleration)	D
   The noise described by the customer could not be confirmed.	E

   HINT: 

   Perform "Inspection After Repair" after replacing the turbocharger sub-assembly.

   Refer to INITIALIZATION [09/2022 - ]

Result: 

A 

REPLACE TURBOCHARGER SUB-ASSEMBLY 

Refer to REMOVAL [09/2022 - ]

HINT: 

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

  When the waste gate valve rod is pressed down and a change in the abnormal noise occurs, there is a possibility of metallic sounds being caused by wear due to looseness spreading in the waste gate valve actuator assembly, waste gate valve rod and waste gate valve connections wear.

• When the waste gate valve rod is pressed down and there is no change in noise, there is a possibility of metallic sounds being caused by wear due to looseness spreading in the waste gate valve wear.

Result: 

C 

See step  8

Result: 

D 

See step  12

Result: 

E 

See step  17

Result: 

B 

See step  4

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

   Refer to INSPECTION [09/2022 - ]

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

   Refer to INSPECTION [09/2022 - ]

   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

   0.20 mm (0.007874 in.) or less

   Result

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

   HINT: 

   Perform "Inspection After Repair" after replacing the turbocharger sub-assembly.

   Refer to INITIALIZATION [09/2022 - ]

Result: 

B 

REPLACE TURBOCHARGER SUB-ASSEMBLY. Refer to  REMOVAL [09/2022 - ] 

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

   HINT: 

   Perform "Inspection After Repair" after replacing the turbocharger sub-assembly.

   Refer to INITIALIZATION [09/2022 - ]

Result: 

B 

REPLACE TURBOCHARGER SUB-ASSEMBLY. Refer to  REMOVAL [09/2022 - ] 

Result: 

A 

See step  6

Refer to REMOVAL [09/2022 - ]

Result

Result: 

NEXT 

See step  7

1. Check that the abnormal noise has disappeared.

   Result

   Proceed to
   NEXT

Result: 

NEXT 

END 

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 or oil adhering around the V band (A in the illustration)	B
   Oil adhering to the compressor flange or hose clamp (B in the illustration)	C

   HINT: 

   Perform "Inspection After Repair" after replacing the turbocharger sub-assembly.

   Refer to INITIALIZATION [09/2022 - ]

Result: 

B 

REPLACE TURBOCHARGER SUB-ASSEMBLY. Refer to  REMOVAL [09/2022 - ] 

Result: 

C 

See step  11

Result: 

A 

See step  9

Refer to REMOVAL [09/2022 - ]

Result

Result: 

NEXT 

See step  10

1. Check that the abnormal noise has disappeared.

   Result

   Proceed to
   NEXT

Result: 

NEXT 

END 

1. Repair or replace the parts that are leaking oil.

   HINT: 

   • If oil leaks from the contact surface between the compressor inlet elbow and the compressor housing, the installation may be incorrect due to loose nuts or a defective gasket. Check the installation or replace the gasket.
   • If oil leaks from the hose clamp part of compressor outlet, the installation may be incorrect due to loose clamp or defective hose. Check the installation or replace the hose and clamp.

   Result

   Proceed to
   NEXT

Result: 

NEXT 

END 

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

   Refer to INSPECTION [09/2022 - ]

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

   Refer to INSPECTION [09/2022 - ]

   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

   0.20 mm (0.007874 in.) or less

   Result

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

   HINT: 

   Perform "Inspection After Repair" after replacing the turbocharger sub-assembly.

   Refer to INITIALIZATION [09/2022 - ]

Result: 

B 

REPLACE TURBOCHARGER SUB-ASSEMBLY. Refer to  REMOVAL [09/2022 - ] 

Result: 

A 

See step  13

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 with bearing housing sub-assembly and determine if the noise improved.

   Result

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

   HINT: 

   Perform "Inspection After Repair" after replacing the turbocharger sub-assembly.

   Refer to INITIALIZATION [09/2022 - ]

Result: 

B 

REPLACE TURBOCHARGER SUB-ASSEMBLY. Refer to  REMOVAL [09/2022 - ] 

Result: 

A 

See step  14

Refer to REMOVAL [09/2022 - ]

Result

Result: 

NEXT 

See step  15

1. Check that the abnormal noise has disappeared.

   Result

   Result	Proceed to
   Abnormal noise has disappeared	A
   Noise occurs (whistling sound)	B

Result: 

A 

END 

Result: 

B 

See step  16

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