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Inspection [03/2019 - ]: Procedure

  1. FAULT CAUSES ON THE TURBOCHARGER SUB-ASSEMBLY 
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  2. BEARING DAMAGE 
    1. If the compressor or turbine wheel rub against the housing (see picture below), the turbocharger sub-assembly is faulty. This damage leads not only to a drop below the charging pressure but also noises.
      GTY945789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Traces left by the impeller grinding against the housing.
  3. FOREIGN BODY ON THE TURBINE SIDE 
    1. If a foreign body damages the turbine wheel, the efficiency of the turbocharger sub-assembly is severely limited and the required charging pressure is no longer reached. Where a foreign body causes damage on the turbine side, the adjustment vanes are usually also damaged in addition to the turbine wheel, which often causes the adjusting mechanism to jam.
    2. In the event of damage caused by a foreign body, it is imperative to establish how the foreign body penetrated the system and to remedy the cause, as otherwise the newly installed turbocharger sub-assembly may also be damaged.
    3. Normal turbine wheel without damage.
      GTY945794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Normal turbine wheel without damage.
      GTY945754Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Turbine vanes damaged by foreign bodies.
      GTY945792Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. FOREIGN BODY ON THE COMPRESSOR SIDE 
    1. If a foreign body damages the impeller, the efficiency of the turbocharger sub-assembly is severely limited and the required charging pressure is no longer reached.
    2. In the event of damage caused by a foreign body, it is imperative to establish how the foreign body penetrated the system and to remedy the cause, as otherwise the newly installed turbocharger sub-assembly may also be damaged.

      HINT: 

      Slight discoloration and shiny patches on the impeller arise normally during production and in operation, see the following image.

    3. Normal impeller without damage.
      GTY945696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Impeller damaged by foreign bodies.
      GTY945757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Impeller damaged by foreign bodies.
      GTY945795Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. COMPRESSOR PUMPING 
    1. The phenomenon referred to as compressor pumping can occur if the charging pressure becomes too high where there is low air mass flow. The air current at the compressor is severed abruptly and a pulsating current develops. This current can damage the compressor and cause disruptive noises.
    2. Charger pumping may occur due to defects that obstruct the air mass flow in the charge air guide or cause excessive charging pressure.
  6. EXTERNAL CORROSION 
    1. External corrosion on the turbine housing is not a cause for concern. External corrosion on the adjusting mechanism is also not a cause for concern as long as the function of the adjusting mechanism is OK. The function of the adjusting mechanism must be checked through the diagnosis system.
  7. OIL CRUSTING ON THE COMPRESSOR INTAKE 
    1. If the oil content in the blow-by gas is too high, heavy oil crusting may form on the compressor. In this case, the cause of the excessive oil content must be remedied.
    2. Normal oil accumulations in the diffuser of the compressor.
      GTY945690Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Heavy oil crusting in the diffuser of the compressor.
      GTY945755Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. OIL GRADE 
    1. Oil of poor quality can break down and form deposits in the oil circuit. This can lead to insufficient lubrication of the turbocharger sub-assembly. Only BMW approved oil may be used.
      GTY945691Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Oil deposits in the oil return
  9. CHARGE AIR ROUTING HAS A LEAK 
    1. In the event of leakage in the charge air routing, the charging pressure and thus the power of the engine falls. Noises may also arise.
      GTY945756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Leaky charge air routing caused by a damaged hose.
      GTY945759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. AIR CLEANER CLOGGED/FAULTY OR SUCTION DUCT NARROWED 
    1. If the air intake duct is blocked (for example the air cleaner is clogged/faulty or the air intake hose has collapsed etc.), this leads to a lack of air in the compressor. As a result, the compressor is not able to generate the charging pressure.
    2. This fault almost always results in serious overspeeding of the turbocharger sub-assembly.
      GTY945774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Example: Faulty air cleaner with damaged fins (air cleaner contracts under load and blocks the air intake duct).
  11. WIRING OF THE TURBOCHARGER ACTUATOR AND LINK ASSEMBLY IS FAULTY 
    1. If the wiring of the turbocharger actuator and link assembly is faulty, the engine control cannot activate the turbocharger actuator and link assembly properly. This can have various effects (excessively high charging pressure, excessively low charging pressure, poor response characteristics).
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