Turbocharger system diagnostics guide

TURBOCHARGER SYSTEM CHECK
Noise

Perform a reproduction test to reproduce the vehicle noise at conditions described by end-user and
measured inside the vehicle cabin. Vehicle can be tested outside the garage only. Following driving
conditions should be considered:

  • at Parking lot & at Driving at specific gear / steady speed & at acceleration / deceleration
  • Perform test with Cold & Hot engine
  • Capture a noise record inside the cabin at each listed condition
  • Share test results with your OEM contact for a further resolution
Connections

In addition to the verifications performed during preliminary inspection, look at tightening, alignment and integrity of all linked components, such as thermal shields, attachments for cable ducts, sensors, caches and engine protections, including wheel arches

Action: Repair linked components as necessary, turbocharger need not be replaced unless damaged due to consequence.
If issue is not resolved continue analysis.

Connections

Leak at Turbocharger connection

Action: Repair linked components as necessary, turbocharger need not be replaced unless damaged due to consequence.
If issue is not resolved continue analysis.

COMPONENTS

Check the absence of leaks, tears, holes, cracks or porosities of air inlet circuit components.

Action: Repair linked components as necessary, turbocharger need not be replaced unless damaged due to consequence.
If issue is not resolved continue analysis.

COMPONENTS

Damaged boost pipe

Action: Repair linked components as necessary, turbocharger need not be replaced unless damaged due to consequence.
If issue is not resolved continue analysis.

COMPONENTS

Damaged exhaust pipe

Action: Repair linked components as necessary, turbocharger need not be replaced unless damaged due to consequence.
If issue is not resolved continue analysis.

COMPONENTS

Drive belt loose or worn out causing high pitch noise varying with engine speed
Note: Refer OEM service manual for further details

Action: Repair linked components as necessary, turbocharger need not be replaced unless damaged due to consequence.
If issue is not resolved continue analysis.

COMPONENTS

EGR valve wear causing clicling noise
Note: Refer OEM service manual for further details

Action: Repair linked components as necessary, turbocharger need not be replaced unless damaged due to consequence.
If issue is not resolved continue analysis.

ROTOR EXCESSIVE MOVEMENT / GENERIC DAMAGE
  • Rotor excessive movement may be checked only visually to confirm no trace of Compressor
    wheel contact with housing. Contact is confirmed only when burrs found on Compressor
    wheel blade edges.
  • Manual testing of shaft movement from side to side does not confirm excessive movement
    and is not allowed.
  • Check Compressor wheel for blade damage due to foreign object

Action: If not ok the turbo charger must be replaced.
If issue is not resolved continue analysis.

Clicking / Rattling noise (mechanical noise)

Perform check of engine components for source of mechanical noise.

Perform check of turbo components, when engine parts are conform:

  • Actuator & Kinematics / Recirculation Valve

Take video record and share with Hotline & supplier. Turbo to be
replaced only when agreed with Hotline or supplier

Look for other source of Performance - Contact the respective regional OEM Service Engineer.

Noise
Connections
COMPONENTS
ROTOR EXCESSIVE MOVEMENT / GENERIC DAMAGE
Clicking / Rattling noise (mechanical noise)