RM3660EC _51 Engine / Hybrid System _080777 NR Series ENGINE CONTROL _0393969 SFI SYSTEM J

NR Series ENGINE CONTROL  SFI SYSTEM  Turbocharger Noise  


DESCRIPTION

HINT:

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
HINT:
·

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.




Faults and Symptoms of Gasoline 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

HINT:

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
HINT:

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



PROCEDURE

1.CONFIRM CONDITION IN WHICH NOISE OCCURRED
a.

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
Transaxle 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
2.CHECK DTC OUTPUT
a.

Connect the GTS to the DLC3.


b.

Start the engine.


c.

Turn the GTS on.


d.

Enter the following menus: Powertrain / Engine / Trouble Codes.


e.

Check DTCs.

Powertrain > Engine > Trouble Codes
50001 372
Result:
Result Proceed to
DTCs are not output A
DTCs are output B


HINT:
·

Check whether DTCs related to the turbo pressure sensor or atmospheric pressure sensor are output.

·

If a DTC related to the turbo pressure sensor or atmospheric pressure sensor is output, defective actuator control related to the turbocharger may be the cause of the noise.





A

3.PERFORM SIMULATION TEST

B

GO TO DTC CHART

Click hereEngine / Hybrid System>NR Series (ENGINE CONTROL)>SFI SYSTEM>DIAGNOSTIC TROUBLE CODE CHART


3.PERFORM SIMULATION TEST
a.

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.



b.

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 or the noise of a level that cannot be heard while driving with closing all the windows occurs. G



A

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

B

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

C

11.CHECK TURBOCHARGER SUB-ASSEMBLY

D

17.INSPECT AIR BY-PASS VALVE ASSEMBLY

E

20.REPLACE TURBOCHARGER SUB-ASSEMBLY

F

22.CHECK GEAR NOISE

G

23.EXPLAIN TO CUSTOMER THAT SOUND IS NORMAL
4.CHECK TURBOCHARGER SUB-ASSEMBLY (INSPECT WASTE GATE VALVE ACTUATOR AND ACTUATOR ROD)
a.

Check the installation condition of the E-ring on the link connection of the waste gate valve actuator and turbine housing.


b.

Check the actuator rod for the waste gate valve actuator.

HINT:
·

Actuator rod wear may cause looseness leading to a chattering sound (metallic sound).

·

Compare with another vehicle of the same model which is not malfunctioning to see if there is any difference in the operation sound.




Result:
Result Proceed to
No actuator rod malfunction A
Actuator rod malfunction B



A

5.CHECK TURBOCHARGER SUB-ASSEMBLY (INSPECT COMPRESSOR IMPELLER AND COMPRESSOR HOUSING)

B

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

Click hereEngine / Hybrid System>NR Series (INTAKE / EXHAUST)>TURBOCHARGER>REMOVAL


5.CHECK TURBOCHARGER SUB-ASSEMBLY (INSPECT COMPRESSOR IMPELLER AND COMPRESSOR HOUSING)
a.

Check for damage to the compressor impeller.


b.

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 TURBOCHARGER)

B

REPLACE TURBOCHARGER SUB-ASSEMBLY (COMPRESSOR IMPELLER OR COMPRESSOR HOUSING MALFUNCTION)

Click hereEngine / Hybrid System>NR Series (INTAKE / EXHAUST)>TURBOCHARGER>REMOVAL


6.CHECK TURBOCHARGER SUB-ASSEMBLY (INSPECT TURBINE SHAFT)
a.

Check that the turbine shaft rotates smoothly, without catching.

Click hereEngine / Hybrid System>NR Series (INTAKE / EXHAUST)>TURBOCHARGER>INSPECTION


b.

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

Click hereEngine / Hybrid System>NR Series (INTAKE / EXHAUST)>TURBOCHARGER>INSPECTION

HINT:

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



A

7.CHECK TURBOCHARGER SUB-ASSEMBLY (INSPECT COMPRESSOR IMPELLER AND COMPRESSOR HOUSING)

B

REPLACE TURBOCHARGER SUB-ASSEMBLY (TURBINE SHAFT MALFUNCTION)

Click hereEngine / Hybrid System>NR Series (INTAKE / EXHAUST)>TURBOCHARGER>REMOVAL


7.CHECK TURBOCHARGER SUB-ASSEMBLY (INSPECT COMPRESSOR IMPELLER AND COMPRESSOR HOUSING)
a.

Check for damage to the compressor impeller.


b.

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

8.INSPECT AIR BY-PASS VALVE ASSEMBLY

B

REPLACE TURBOCHARGER SUB-ASSEMBLY (COMPRESSOR IMPELLER OR COMPRESSOR HOUSING MALFUNCTION)

Click hereEngine / Hybrid System>NR Series (INTAKE / EXHAUST)>TURBOCHARGER>REMOVAL


8.INSPECT AIR BY-PASS VALVE ASSEMBLY
a.

Inspect the air by-pass valve assembly.

Click hereEngine / Hybrid System>NR Series (INTAKE / EXHAUST)>TURBOCHARGER>INSPECTION


HINT:
·

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 turbocharger sub-assembly and determine if the noise improved.



Result:
Proceed to
OK
NG



OK

9.REPLACE TURBOCHARGER SUB-ASSEMBLY

NG

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

Click hereEngine / Hybrid System>NR Series (INTAKE / EXHAUST)>TURBOCHARGER>REMOVAL


9.REPLACE TURBOCHARGER SUB-ASSEMBLY
a.

Replace the turbocharger sub-assembly.

Click hereEngine / Hybrid System>NR Series (INTAKE / EXHAUST)>TURBOCHARGER>REMOVAL


Result:
Proceed to
NEXT



NEXT

10.PERFORM SIMULATION TEST
10.PERFORM SIMULATION TEST
a.

Check that the abnormal noise has disappeared.


Result:
Proceed to
NEXT



NEXT

END

11.CHECK TURBOCHARGER SUB-ASSEMBLY
a.

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

A425209E01
2,0.375 2.156,0.573 0.156,0.198 10 true A 2.729,2.396 2.885,2.594 0.156,0.198 10 true A 3.292,0.813 3.448,1.01 0.156,0.198 10 true A 3.01,2.281 3.167,2.479 0.156,0.198 10 true B 3.906,1.26 4.063,1.458 0.156,0.198 10 true C 5.323,3.104 5.479,3.302 0.156,0.198 10 true C

HINT:

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


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
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. C
Oil is leaking from the compressor housing in any of the areas (C) shown in the illustration. D




A

12.REPLACE TURBOCHARGER SUB-ASSEMBLY

B

14.CHECK EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

C

REPLACE TURBOCHARGER SUB-ASSEMBLY

Click hereEngine / Hybrid System>NR Series (INTAKE / EXHAUST)>TURBOCHARGER>REMOVAL


D

CHECK AND REPAIR AIR TUBE OR HOSE CLAMP

12.REPLACE TURBOCHARGER SUB-ASSEMBLY
a.

Replace the turbocharger sub-assembly.

Click hereEngine / Hybrid System>NR Series (INTAKE / EXHAUST)>TURBOCHARGER>REMOVAL

HINT:

As the waste gate valve actuator or air by-pass valve assembly is malfunctioning, it is necessary to replace the turbocharger sub-assembly.



Result:
Proceed to
NEXT



NEXT

13.PERFORM SIMULATION TEST
13.PERFORM SIMULATION TEST
a.

Check that the abnormal noise has disappeared.


Result:
Proceed to
NEXT



NEXT

END

14.CHECK EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
a.

Check for deformation or cracks in the mounting surfaces on the exhaust manifold converter sub-assembly and the turbine housing.

HINT:

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 mounting surface C




A

15.REPLACE GASKET

B

REPLACE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

Click hereEngine / Hybrid System>NR Series (EMISSION CONTROL)>MONOLITHIC CONVERTER>REMOVAL


C

REPLACE TURBOCHARGER SUB-ASSEMBLY

Click hereEngine / Hybrid System>NR Series (INTAKE / EXHAUST)>TURBOCHARGER>REMOVAL


15.REPLACE GASKET
a.

Replace the exhaust gasket.


Result:
Proceed to
NEXT



NEXT

16.PERFORM SIMULATION TEST
16.PERFORM SIMULATION TEST
a.

Check that the abnormal noise has disappeared.


Result:
Proceed to
NEXT



NEXT

END

17.INSPECT AIR BY-PASS VALVE ASSEMBLY
a.

Inspect the air by-pass valve assembly.

Click hereEngine / Hybrid System>NR Series (INTAKE / EXHAUST)>TURBOCHARGER>INSPECTION

HINT:

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



Result:
Proceed to
OK
NG



OK

18.READ VALUE USING GTS (ATMOSPHERIC PRESSURE)

NG

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

Click hereEngine / Hybrid System>NR Series (INTAKE / EXHAUST)>TURBOCHARGER>REMOVAL


18.READ VALUE USING GTS (ATMOSPHERIC PRESSURE)
a.

Connect the GTS to the DLC3.


b.

Turn the GTS on.


c.

Turn the ignition switch to ON.


d.

Enter the following menus: Powertrain / Engine / Data List / Atmospheric Pressure.

Powertrain > Engine > Data List
Tester Display
Atmospheric Pressure
50003 372 229

e.

Using the table, read the normal atmospheric pressure value for the applicable altitude and temperature.

A337505

HINT:
·

Standard atmospheric pressure is approximately 101 kPa(abs) (15 psi(abs)).

·

For every 100 m (328 ft.) increase in altitude, atmospheric pressure drops by approximately 1 kPa (0.15 psi). This varies by weather.




f.

Compare the Atmospheric pressure value in the Data List with the normal atmospheric value from the table.

Result:
Result Proceed to
Other than the following A
Difference between Atmospheric Pressure in the Data List and normal atmospheric pressure value is 10 kPa (1.45 psi) or more. B




A

19.CHECK NO. 1 TURBO PRESSURE SENSOR

B

REPLACE ECM

Click hereEngine / Hybrid System>NR Series (ENGINE CONTROL)>ECM>REMOVAL


20.REPLACE TURBOCHARGER SUB-ASSEMBLY
a.

Replace the turbocharger sub-assembly.

Click hereEngine / Hybrid System>NR Series (INTAKE / EXHAUST)>TURBOCHARGER>REMOVAL

HINT:

As the turbine shaft play is not appropriate or the compressor impeller is malfunctioning, it is necessary to replace the turbocharger sub-assembly.



Result:
Proceed to
NEXT



NEXT

21.PERFORM SIMULATION TEST
21.PERFORM SIMULATION TEST
a.

Check that the abnormal noise has disappeared.


Result:
Proceed to
NEXT



NEXT

END

22.CHECK GEAR NOISE
a.

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

23.EXPLAIN TO CUSTOMER THAT SOUND IS NORMAL
a.

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.

·

Function sound is reduced so as not to be transmitted to the passenger compartment by sound insulation material, windows, etc.




Result:
Proceed to
NEXT



NEXT

END