Toyota Yaris: Sfi System / Turbocharger Noise

Toyota Yaris XP210 (2020-2024) Reapir and Service Manual / Engine & Hybrid System / G16e-gts (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 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
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 that the sound was a malfunction?

Proceed to

2.	CHECK DTC OUTPUT

(a) Check the DTCs.

Powertrain > Engine > Trouble Codes

Result	Proceed to
DTC is not output	A
DTCs are output	B

HINT:

Check whether a DTC is stored related to the boost pressure sensor or atmospheric pressure sensor (in ECU).
If a DTC is stored related to the boost pressure sensor or atmospheric pressure sensor (in ECU), defective actuator control related to the turbocharger may be the cause of the turbocharger noise.

GO TO DTC 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	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 (whistling or foghorn-like (airflow sound) during acceleration or deceleration)	D
The noise described by the customer could not be confirmed.	E

HINT:

Perform "Inspection After Repair" after replacing the turbocharger sub-assembly.

Click here

REPLACE TURBOCHARGER SUB-ASSEMBLY

GO TO STEP 8

GO TO STEP 12

GO TO STEP 17

4.	CHECK TURBOCHARGER SUB-ASSEMBLY

(a) Check that the turbine shaft rotates smoothly, without catching.

Click here

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

Click here

HINT:

If the turbine shaft catches or if there no play or excessive play, it could indicate poor sliding due to seal damage due to seizing or a deposit build-up.

Standard value:

0.10 mm (0.00394 in.) or less

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

HINT:

Perform "Inspection After Repair" after replacing the turbocharger sub-assembly.

Click here

REPLACE TURBOCHARGER SUB-ASSEMBLY

5.	CHECK TURBOCHARGER SUB-ASSEMBLY

(a) Check for damage to the compressor impeller.

(b) Check for interference between the compressor impeller and the compressor housing.

Result	Proceed to
No damage or interference	A
Damage or interference exists	B

HINT:

Perform "Inspection After Repair" after replacing the turbocharger sub-assembly.

Click here

REPLACE TURBOCHARGER SUB-ASSEMBLY

6.	REPLACE TURBOCHARGER SUB-ASSEMBLY

Click here

7.	PERFORM SIMULATION TEST

(a) Check that the abnormal noise has disappeared.

END

8.	CHECK TURBOCHARGER SUB-ASSEMBLY

(a) Check that no soot or oil adheres to the turbocharger sub-assembly connectors.

HINT:

If adhering soot or an oil leak exists, air leaking at that position may be the cause of the abnormal noise.

Result	Proceed to
No adhering soot or an oil	A
Soot adhering around the turbine housing, flange, or V band (A in the illustration)	B
Oil leak from the contact surface between the compressor housing and the seal plate or between the seal plate and the bearing housing (B in the illustration)	B
Oil adhering to the compressor flange (C in the illustration)	C

HINT:

Perform "Inspection After Repair" after replacing the turbocharger sub-assembly.

Click here

REPLACE TURBOCHARGER SUB-ASSEMBLY

GO TO STEP 11

9.	REPLACE TURBOCHARGER SUB-ASSEMBLY

Click here

10.	PERFORM SIMULATION TEST

(a) Check that the abnormal noise has disappeared.

END

11.	REPAIR OR REPLACE DEFECTIVE PARTS (PARTS LEAKING OIL)

(a) Repair or replace the parts that are leaking oil.

HINT:

If oil leaks from the contact surface between the compressor inlet elbow and the compressor housing, the installation may be incorrect due to loose nuts or a defective gasket. Check the installation or replace the gasket.
If oil leaks from the contact surface between the compressor outlet elbow and the compressor housing, the installation may be incorrect due to loose nuts or a defective gasket. Check the installation or replace the gasket.

END

12.	CHECK TURBOCHARGER SUB-ASSEMBLY

(a) Check that the turbine shaft rotates smoothly, without catching.

Click here

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

Click here

HINT:

If the turbine shaft catches or if there no play or excessive play, it could indicate poor sliding due to seal damage due to seizing or a deposit build-up.

Standard value:

0.10 mm (0.00394 in.) or less

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

HINT:

Perform "Inspection After Repair" after replacing the turbocharger sub-assembly.

Click here

REPLACE TURBOCHARGER SUB-ASSEMBLY

13.	CHECK TURBOCHARGER SUB-ASSEMBLY

(a) Check for damage to the compressor impeller.

(b) Check for interference between the compressor impeller and the compressor housing.

HINT:

If the previous checks find no malfunction, replace the compressor with bearing housing sub-assembly and determine if the noise improved.

Result	Proceed to
No damage or interference	A
Damage or interference exists	B

HINT:

Perform "Inspection After Repair" after replacing the turbocharger sub-assembly.

Click here

REPLACE TURBOCHARGER SUB-ASSEMBLY

14.	REPLACE TURBOCHARGER SUB-ASSEMBLY

Click here

15.	PERFORM SIMULATION TEST

(a) Check that the abnormal noise has disappeared.

Result	Proceed to
Abnormal noise has disappeared	A
Noise occurs (whistling sound)	B

END

16.	CHECK GEAR NOISE

(a) Check if the gear noise is the source of the abnormal noise (not the noise from the turbocharger).

ELIMINATE THE CAUSE OF THE NOISE

17.	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.

END

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