SFI SYSTEM Lack of Power (Turbocharger System)

CAUTION / NOTICE / HINT

PROCEDURE

1. CHECK TURBOCHARGER SUB-ASSEMBLY

   1. Check for oil leaks and large carbon deposits around the connecting surfaces of the turbocharger sub-assembly.

      

      Tip:

      If oil leaks or a large amount of carbon deposits exist, air leaks from the respective sealing surfaces may be causing the lack of boost pressure.

   Result

   Result	Proceed to
   An oil leak or large amount of carbon deposits does not exist.	A
   A large amount of carbon deposits exist around the turbine housing, flange or gaskets in any of the areas (A) shown in the illustration.	B
   A large amount of carbon deposits exist around the waste gate valve link.	C
   Oil is leaking from between the sealing surfaces of the seal plate and compressor housing or bearing housing in the area (B) shown in the illustration.	D
   Oil is leaking from the compressor housing in any of the areas (C) shown in the illustration.	E

   B

   CHECK EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLYClick here

   C

   CHECK TURBOCHARGER SUB-ASSEMBLY (INSPECT TURBINE HOUSING)Click here

   D

   REPLACE TURBOCHARGER SUB-ASSEMBLY

   Click here

   E

   CHECK AND REPAIR AIR TUBE OR HOSE CLAMP

   A

2. CHECK TURBOCHARGER SUB-ASSEMBLY (INSPECT TURBINE SHAFT)

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

      Click here

      Tip:

      If the turbine shaft catches or there is no play, seal failure due to seizure or improper operation due to accumulation of deposits is suspected.

   Result

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

   B

   REPLACE TURBOCHARGER SUB-ASSEMBLY (TURBINE SHAFT MALFUNCTION)

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   A

3. CHECK TURBOCHARGER SUB-ASSEMBLY (INSPECT WASTE GATE VALVE)

   1. Use a vacuum pump to apply -35 +/-4.0 kPa (-263 +/-35 mmHg) negative pressure to the diaphragm chamber and check that the waste gate valve seats.

      Note:

      Do not apply a negative pressure of -65 kPa (-488 mmHg) 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 (-263 mmHg) negative pressure	A
   Seats at -35 kPa (-263 mmHg) or greater negative pressure	B
   Waste gate valve does not move	C

   B

   REPLACE TURBOCHARGER SUB-ASSEMBLY (WASTE GATE VALVE ACTUATOR MALFUNCTION)

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   C

   REPLACE TURBOCHARGER SUB-ASSEMBLY (WASTE GATE VALVE MALFUNCTION)

   Click here

   A

4. CHECK TURBOCHARGER SUB-ASSEMBLY (INSPECT WASTE GATE VALVE)

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

      Standard

      Play exists

      Tip:

      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

      0.15 mm (0.0059 in.) or less

   Result

   Proceed to
   OK
   NG

   NG

   REPLACE TURBOCHARGER SUB-ASSEMBLY (WASTE GATE VALVE MALFUNCTION)

   Click here

   OK

5. CHECK TURBOCHARGER SUB-ASSEMBLY (INSPECT AIR BY-PASS VALVE)

   1. Inspect the air by-pass valve.

      Click here

   Result

   Proceed to
   OK
   NG

   OK

   PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE

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   NG

   REPLACE TURBOCHARGER SUB-ASSEMBLY (AIR BY-PASS VALVE MALFUNCTION)

   Click here

6. 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.

      Tip:

      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

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   C

   REPLACE TURBOCHARGER SUB-ASSEMBLY

   Click here

   A

7. REPLACE GASKET

   1. Replace the gasket between the exhaust manifold converter sub-assembly and turbocharger sub-assembly.

   Result

   Proceed to
   NEXT

   NEXT

8. PERFORM SIMULATION TEST

   1. Check that the abnormal state has disappeared.

   Result

   Proceed to
   NEXT

   NEXT

   END

9. CHECK TURBOCHARGER SUB-ASSEMBLY (INSPECT TURBINE HOUSING)

   1. Check that the bushing of the turbine housing waste gate valve link is free of cracks and the play does not exceed 0.15 mm (0.0059 in.).

      Standard

      No cracks and play does not exceed 0.15 mm (0.0059 in.)

   Result

   Proceed to
   OK
   NG

   OK

   PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE

   Click here

   NG

   REPLACE TURBOCHARGER SUB-ASSEMBLY (TURBINE HOUSING MALFUNCTION)

   Click here