Turbocharger system diagnostics guide

TURBOCHARGER SYSTEM CHECK
Tuning

Check ECU history for modifications

Action: If not ok the turbo charger must be replaced without warranty.
If issue is not resolved continue analysis.

Tuning

Check unauthorized adjustment of the actuator rod end.

Action: If not ok the turbo charger must be replaced without warranty.
If issue is not resolved continue analysis.

Tuning

Check unauthorized adjustment of the flow screw.

Action: If not ok the turbo charger must be replaced without warranty.
If issue is not resolved continue analysis.

Tuning

The Paint seal should not be broken.

Action: If not ok the turbo charger must be replaced without warranty.
If issue is not resolved continue analysis.

Actuator movement, calibration & hysteresis

Check actuator connections

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

Actuator movement, calibration & hysteresis
  • Check Actuator for a smooth movement by key-on and with varying rpm, validate the absence of sticking condition
  • Check Actuator calibration indirectly with ECU

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

Engine Boost

Run the car in such condition that you may reproduce the failure.

Action: If turbo boost follows engine requirement, the turbocharger cannot be claimed and changed.
If issue is not resolved continue analysis.

Engine Boost

Measure engine boost set point & Turbo response.
Note: Refer OEM guide

Action: If turbo boost follows engine requirement, the turbocharger cannot be claimed and changed.
If issue is not resolved continue analysis.

Engine Boost

Compare both curves / Values.
Note: Refer OEM guide

Action: If turbo boost follows engine requirement, the turbocharger cannot be claimed and changed.
If issue is not resolved continue analysis.

Other Components

Flow sensor
Note: Refer OEM service manual for further details

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

Other Components

EGR Valves
Note: Refer OEM service manual for further details

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

Other Components

Modulation valve (including piping)
Note: Refer OEM service manual for further details

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

Other Components

Injection unit
Note: Refer OEM service manual for further details

Action: If damaged, replace turbo or RCV service kit, if available.
If issue is not resolved continue analysis.

Other Components

Check Recirculation valve(RCV) functionality with the open/close test using a control from the ECU

Replace turbo or RCV service kit if available

Compressor wheel damage

Disconnect Compressor Air inlet pipe.

Action: If damaged, the turbo charger must be replaced The entire air circuit must be cleaned or changed to avoid new failure in case of foreign object The foreign object can be found in the heat exchanger.
If issue is not resolved continue analysis.

Compressor wheel damage

Inspect compressor wheel blade, there should be no visible damage.

Action: If damaged, the turbo charger must be replaced The entire air circuit must be cleaned or changed to avoid new failure in case of foreign object The foreign object can be found in the heat exchanger.
If issue is not resolved continue analysis.

Rotor Free Rotation

Rotor may be turned by Compressor wheel using a soft
tool only to avoid Compressor wheel blades damage

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

Rotor Excessive Movement
  • 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.

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

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

Tuning
Actuator movement, calibration & hysteresis
Engine Boost
Other Components
Compressor wheel damage
Rotor Free Rotation
Rotor Excessive Movement