SFI SYSTEM(w/ Canister Pump Module) Turbocharger Noise

DESCRIPTION

Tech Tips

Turbocharger noise is classified into two types. These are whistling sound and chattering sound. During troubleshooting, first determine the type of noise.

Type of Abnormal Noise Outline of Abnormal Noise Major Trouble Area
Whistling sound (airflow sound) The whistling sound volume and pitch are proportional to the turbocharger or engine speed. The abnormal noise level becomes clear when the engine speed is increased.

  • Turbocharger (example: unstable shaft)

  • Transmission gears

  • Leak in intake system

  • Damaged intake system
Chattering sound (metallic sound) The chattering sound pitch is lower than the whistling sound pitch. Has a comparatively constant pitch that is independent of the engine speed and vehicle speed.

Turbocharger

Tech Tips


  • The turbocharger vibrations are transmitted to the exhaust pipe, causing noise and resonance.

  • The turbocharger vibrations are transmitted through the exhaust pipe to the chassis (floor), causing noise and resonance in the chassis.

  1. Faults and Symptoms of Diesel Engine Components

    Turbocharger system
    Main fault

    • Unstable turbocharger turbine shaft (interference, seizing, poor balance, etc.)

    • Poor installation or defective operation of the waste gate valve.

    • Poor installation or defective operation of the air by-pass valve assembly.
    Symptom

    • High-pitched whistling sound

      Tech Tips

      The volume and pitch are proportional to the turbocharger speed.

    • Metallic sound due to looseness
    Intake system
    Main fault Leak
    Symptom Abnormal noise during intake leak
    Transmission gears
    Symptom

    Gear noise

    Tech Tips

    The volume and pitch are proportional to the transmission gear speed.

PROCEDURE


  1. CONFIRM CONDITION IN WHICH NOISE OCCURRED


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

      Tech Tips

      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

    NEXT

  2. CHECK DTC OUTPUT


    1. Connect the GTS to the DLC3.

    2. Turn the engine switch on (IG).

    3. Turn the GTS 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

      Tech Tips


      • 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.


    B

    GO TO DTC CHART Click here

    A

  3. PERFORM SIMULATION TEST


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

      Tech Tips

      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

    B

    CHECK COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY Click here

    C

    CHECK TURBOCHARGER SUB-ASSEMBLY Click here

    D

    CHECK AIR BY-PASS VALVE ASSEMBLY Click here

    E

    CHECK COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY Click here

    F

    CHECK GEAR NOISE Click here

    G

    EXPLAIN TO CUSTOMER THAT SOUND IS NORMAL Click here

    A

  4. CHECK WASTE GATE VALVE ACTUATOR WITH BRACKET ASSEMBLY


    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.

      Tech Tips

      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.

      Tech Tips

      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

    B

    REPLACE WASTE GATE VALVE ACTUATOR WITH BRACKET ASSEMBLY Click here

    A

  5. CHECK COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY


    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

    A

    END (CAUSE CHECK EXCEPT THE TURBO CHARGER)

    B

    REPLACE COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY Click here

  6. CHECK COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY


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

      Click here

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

      Click here

      Tech Tips

      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

    B

    REPLACE COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY Click here

    A

  7. CHECK COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY


    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

    B

    CHECK COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY Click here

    A

  8. CHECK AIR BY-PASS VALVE ASSEMBLY


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

      Click here

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

      Click here

      Tech Tips


      • 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

    NG

    REPLACE AIR BY-PASS VALVE ASSEMBLY Click here

    OK

  9. REPLACE COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY


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

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  10. PERFORM SIMULATION TEST


    1. Check that the abnormal noise has disappeared.

      Result
      Proceed to
      NEXT

    NEXT

    END

  11. CHECK COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY


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

      Tech Tips

      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

    A

    REPLACE COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY Click here

    B

    REPLACE COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY AND TURBINE HOUSING WITH VALVE SUB-ASSEMBLY Click here

  12. CHECK TURBOCHARGER SUB-ASSEMBLY


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

      B00762WE01

      Tech Tips

      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

    B

    CHECK EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY Click here

    C

    REPLACE COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY Click here

    D

    REPLACE GASKET

    A

  13. CHECK WASTE GATE VALVE ACTUATOR WITH BRACKET ASSEMBLY


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

      Click here

      Tech Tips

      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

    NG

    REPLACE WASTE GATE VALVE ACTUATOR WITH BRACKET ASSEMBLY Click here

    OK

  14. CHECK AIR BY-PASS VALVE ASSEMBLY


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

      Tech Tips


      • 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

    NG

    REPLACE AIR BY-PASS VALVE ASSEMBLY Click here

    OK

  15. REPLACE COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY


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

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  16. PERFORM SIMULATION TEST


    1. Check that the abnormal noise has disappeared.

      Result
      Proceed to
      NEXT

    NEXT

    END

  17. CHECK EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    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.

      Tech Tips

      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

    B

    REPLACE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY Click here

    C

    REPLACE TURBINE HOUSING WITH VALVE SUB-ASSEMBLY Click here

    A

  18. REPLACE EXHAUST PIPE CLAMP AND GASKET


    1. Replace the exhaust pipe clamp and the gasket.

      Result
      Proceed to
      NEXT

    NEXT

  19. PERFORM SIMULATION TEST


    1. Check that the abnormal noise has disappeared.

      Result
      Proceed to
      NEXT

    NEXT

    END

  20. CHECK AIR BY-PASS VALVE ASSEMBLY


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

      Click here

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

      Click here

      Tech Tips

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

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE AIR BY-PASS VALVE ASSEMBLY Click here

    OK

  21. READ VALUE USING GTS (ATMOSPHERIC PRESSURE)


    1. Connect the GTS to the DLC3.

    2. Turn the engine switch on (IG).

    3. Turn the GTS 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.

      B0074BW

      Tech Tips


      • 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 in Data List 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

    B

    REPLACE ECM Click here

    A

  22. INSPECT NO. 2 TURBO PRESSURE SENSOR


    1. Inspect the No. 2 turbo pressure sensor.

      Click here

      Result
      Proceed to
      OK
      NG

    OK

    REPLACE ECM Click here

    NG

    REPLACE NO. 2 TURBO PRESSURE SENSOR Click here

  23. CHECK COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY


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

      Click here

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

      Click here

      Tech Tips

      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

    B

    REPLACE COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY Click here

    A

  24. CHECK COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY


    1. Check for damage to the compressor impeller.

    2. Check for interference between the compressor impeller and the compressor housing.

      Tech Tips

      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

    B

    CHECK COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY Click here

    A

  25. REPLACE COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY


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

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  26. PERFORM SIMULATION TEST


    1. Check that the abnormal noise has disappeared.

      Result
      Proceed to
      NEXT

    NEXT

    END

  27. CHECK COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY


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

      Tech Tips

      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

    A

    REPLACE COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY Click here

    B

    REPLACE COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY AND TURBINE HOUSING WITH VALVE SUB-ASSEMBLY Click here

  28. CHECK GEAR NOISE


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

      Result
      Proceed to
      NEXT

    NEXT

    ELIMINATE THE CAUSE OF THE NOISE

  29. EXPLAIN TO CUSTOMER THAT SOUND IS NORMAL


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

      Tech Tips

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

      Result
      Proceed to
      NEXT

    NEXT

    END