Ecd System (W/ Egr Cooler) Turbocharger Noise

DESCRIPTION

INSPECTION PROCEDURE

CONFIRM CONDITION IN WHICH NOISE OCCURRED

CONFIRM NOISE CUSTOMER MENTIONED (PROCEDURE 2)

CHECK INTAKE SYSTEM

CONFIRM NOISE SOURCE (FROM TURBOCHARGER OR NOT)

CONFIRM THE NOISE TYPE

PERFORM ALIGNMENT OF EXHAUST PIPE AND CONFIRM THE NOISE

CHECK FOR NOISE FROM SOURCE OTHER THAN TURBOCHARGER (PROCEDURE 7)

REPLACE THE PARTS DETECTED IN PROCEDURE 7

CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

EXPLAIN TO THE CUSTOMER THAT THE NOISE IS NORMAL

DESCRIPTION

HINT:

Turbocharger noise is classified into 2 types. One is whistling noise, and the other is whining noise. When troubleshooting, the type of noise should be determined first.

INSPECTION PROCEDURE

1. Confirm with the customer the conditions in which the 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
   Transmission 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 the noise to be abnormal?

1. Check for the noise described by the customer.
   

   HINT:

   If a noise is heard, make sure that the noise matches the noise described by the customer.

   
   

   Result

   Result	Proceed to
   Obvious abnormal noise matching noise described by customer is confirmed	A
   Obvious abnormal noise matching noise described by customer is not confirmed	B

1. Check for air leakage between the air cleaner and turbocharger, and between the turbocharger and intake manifold.
   

   HINT:

   1. Check for disconnected or improperly connected hoses, and gaps between hoses and parts.
      
   2. Check for foreign matter between the air cleaner and turbocharger.
      

1. Connect the intelligent tester to the DLC3.
   

2. Start the engine and warm it up.
   

3. Turn the tester on.
   

4. Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the VN Turbo Open.
   

5. Perform the Active Test and rev the engine up several times.
   

6. Check whether the noise is reduced or not compared with the noise under the condition that the Active Test is not performed.
   
   

   Result

   Result	Proceed to
   The noise is reduced (or disappears)	A
   The noise is the same as in Procedure 2 (The noise does not change)	B

   HINT:

   1. When the variable nozzle of the turbocharger opens fully regardless of the engine condition, the turbocharger speed slows down and the cause of noise can be confirmed that is from the turbocharger or not.
      
   2. If the turbocharger is the cause of the noise, the noise will be reduced when the variable nozzle opens because turbocharger speed does not increase.
      

1. Check whether the noise can be heard even when the engine speed is more than 3000 rpm, and whether the noise gradually gets louder as the engine speed increases.
   

   HINT:

   If so, the noise is likely to be whistling noise. If not, the noise is likely to be whining noise.

   
   

   Result

   Result	Proceed to
   Yes (The noise is likely to be whistling noise)	A
   No (The noise is likely to be whining noise)	B

1. Disconnect the exhaust pipe at the ball joint and from each exhaust pipe support, and then realign the exhaust pipe and reconnect it to each exhaust pipe support and at the ball joint (HILUX_TGN26 RM00000121E00SX.html).
   

HINT:

Above illustration is an example.

2. Confirm whether the noise problem is solved or not.
   

   HINT:

   The alignment of the exhaust pipe affects whining noise.

   
   

   Result

   Result	Proceed to
   The noise problem is solved	A
   The noise problem remains	B

1. Check for the noise source with a sound scope.
   

   NOTICE:

   When performing this check, make sure that the sound scope, your body, etc., do not get caught on the V-belt.

   HINT:

   1. The source of the noise is not the turbocharger, but a part other than the turbocharger (e.g. a part inside the engine, transmission, or vacuum pump).
      
   2. Sometimes gear noise may be mistaken for turbocharger noise. For gear noise, pay attention to the gear inside the engine and transmission gear.
      
   3. Rev the engine up and check if the noise reduces at the same time the engine speed decreases. If the noise reduces at the same time the engine speed decreases, it is gear noise. If the noise reduces a short time after the engine speed decreases, it is turbocharger noise.
      
   4. The following illustration is a reference for checking whether the noise source is from the engine.
      
   
   
   
   
   

   Text in Illustration

   *1	Timing Belt	*2	Camshafts
   *3	Balance Shafts	*4	Crankshaft
   *5	Timing Gear Train	-	-
   *a	Gear Location inside Engine	-	-

   HINT:

   1. Above illustration is an example.
      
   2. Gear noise can be confirmed with a sound scope. Put the sound scope on the cylinder block near the gear, and if the noise heard through the sound scope has the same timing as the noise heard without the sound scope, it is gear noise.
      

1. Replace the parts detected in Procedure 7 as the noise source.
   

1. Check whether the noise problem has been successfully solved.
   

1. Explain to the customer that the noise the customer mentioned is not abnormal.
   

   HINT:

   To help the customer understand, test driving another car with the customer may be helpful.