SFI SYSTEM(w/o Canister Pump Module) Lack of Power (Turbocharger System)

CAUTION / NOTICE / HINT

Tech Tips


  • The diagnosis flowchart is for lack of power due to turbocharger factors.

  • If symptom-specific diagnosis indicates a turbocharger related problem, check using this flowchart.

PROCEDURE


  1. CHECK TURBOCHARGER SUB-ASSEMBLY


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

      B007558E01

      Tech Tips

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

      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
      Soot adhering around the bushing (B in the illustration) C
      Oil leak from the contact surface between the compressor housing and the seal plate or between the seal plate and the bearing housing.(C in the illustration) D
      Oil leak from the compressor housing flange (D in the illustration) E

    B

    CHECK EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY Click here

    C

    CHECK TURBINE HOUSING WITH VALVE SUB-ASSEMBLY Click here

    D

    REPLACE COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY Click here

    E

    REPLACE GASKET

    A

  2. CHECK COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY (TURBINE SHAFT)


    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

    CHECK COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY Click here

    A

  3. CHECK WASTE GATE VALVE ACTUATOR WITH BRACKET ASSEMBLY


    1. Use a vacuum pump to apply -35 +/-4.0 kPa (-5.08 +/-0.58 psi) negative pressure to the diaphragm chamber and check that the waste gate valve seats.

      Note

      Do not apply a negative pressure of -65 kPa (-9.43 psi) or more to the waste gate valve actuator with bracket assembly, as doing so may damage the diaphragm.

      Standard
      Waste gate valve seats without a gap
      Result
      Result Proceed to
      Seats at less than -35 kPa (-5.08 psi) negative pressure A
      Seats at -35 kPa (-5.08 psi) or greater negative pressure B
      Waste gate valve does not move C

    B

    CHECK WASTE GATE VALVE ACTUATOR WITH BRACKET ASSEMBLY Click here

    C

    CHECK WASTE GATE VALVE ACTUATOR WITH BRACKET ASSEMBLY (OPERATION CHECK) Click here

    A

  4. CHECK WASTE GATE VALVE ACTUATOR WITH BRACKET ASSEMBLY


    1. Check for play in the waste gate valve and waste gate valve link.

      Standard
      Play exists

      Tech Tips

      Some play is required as the waste gate valve link slides. If no play exists, the valve is determined to be stuck.

    2. Check for gaps at the waste gate valve contact surface due to scratches, deformation or wear.

      Standard
      0.50 mm (0.0197 in.) or less
      Result
      Proceed to
      OK
      NG

    NG

    REPLACE TURBINE HOUSING WITH VALVE SUB-ASSEMBLY Click here

    OK

  5. CHECK AIR BY-PASS VALVE ASSEMBLY


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

      Click here

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

      Click here

    3. Check for accumulated deposits, deformation and wear on the air by-pass valve assembly contact surfaces (air by-pass valve side and compressor housing side).

      Tech Tips

      A problem with the air by-pass valve assembly contact surfaces may allow air to leak from the damaged position.

      Standard
      0.50 mm (0.0197 in.) or less wear on the contact surface
      Result
      Result Proceed to
      No malfunction discovered during air by-pass valve assembly on-vehicle and individual check No problem with the air by-pass valve assembly contact surface A
      Deformation, wear or accumulated deposits on the compressor housing with bearing sub-assembly contact surface B
      Deformation, wear or accumulated deposits on the air by-pass valve assembly contact surface C
      Malfunction discovered during air by-pass valve assembly on-vehicle and individual check -

    A

    PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE Click here

    B

    REPLACE COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY Click here

    C

    REPLACE AIR BY-PASS VALVE ASSEMBLY Click here

  6. CHECK WASTE GATE VALVE ACTUATOR WITH BRACKET ASSEMBLY


    1. Check the waste gate valve actuator pin for wear.

      Click here

      Standard
      0.50 mm (0.0197 in.) or less

      Tech Tips

      If the wear on the waste gate valve actuator pin does not exceed the standard (no problem with waste gate valve actuator with bracket assembly), the cause may be wear of the waste gate valve link or cracks in the bushing. Replace the turbine housing with valve sub-assembly.

      Result
      Proceed to
      OK
      NG

    OK

    REPLACE TURBINE HOUSING WITH VALVE SUB-ASSEMBLY Click here

    NG

    REPLACE WASTE GATE VALVE ACTUATOR WITH BRACKET ASSEMBLY Click here

  7. CHECK WASTE GATE VALVE ACTUATOR WITH BRACKET ASSEMBLY (OPERATION CHECK)


    1. Move the waste gate valve actuator link and rod by hand to check that they move smoothly (do not stick).

      Click here

      Tech Tips

      If the waste gate valve actuator link and rod move smoothly by hand but the valve does not operate when a negative pressure is applied, there may be damage to the diaphragm, etc. inside the waste gate valve actuator.

      Result
      Result Proceed to
      Waste gate valve actuator link and rod move smoothly by hand (valve does not operate when a negative pressure is applied) A
      Waste gate valve actuator rod does not move smoothly
      Waste gate valve actuator link does not move smoothly B

    A

    REPLACE WASTE GATE VALVE ACTUATOR WITH BRACKET ASSEMBLY Click here

    B

    REPLACE TURBINE HOUSING WITH VALVE SUB-ASSEMBLY Click here

  8. CHECK COMPRESSOR HOUSING WITH BEARING SUB-ASSEMBLY


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

      Click here

      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

  9. 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 turbocharger 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 turbocharger 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

  10. REPLACE EXHAUST PIPE CLAMP AND GASKET


    1. Replace the exhaust pipe clamp and the gasket.

      Result
      Proceed to
      NEXT

    NEXT

  11. PERFORM SIMULATION TEST


    1. Check that the abnormal state has disappeared.

      Result
      Proceed to
      NEXT

    NEXT

    END

  12. CHECK TURBINE HOUSING WITH VALVE SUB-ASSEMBLY


    1. Check that the bushing of the turbine housing waste gate valve link is free of cracks and the play does not exceed 0.50 mm.

      Standard
      No cracks and play does not exceed 0.50 mm (0.0197 in.)
      Result
      Proceed to
      OK
      NG

    OK

    PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE Click here

    NG

    REPLACE TURBINE HOUSING WITH VALVE SUB-ASSEMBLY Click here