Print-Toyota Service Information 11/3/17, 4(26 pm
Print Exit
1GD-FTV ENGINE CONTROL ECD 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
The whistling sound volume and · Turbocharger (example:
pitch are proportional to the unstable shaft)
turbocharger or engine speed. The · Transmission gears
Whistling sound (airflow sound)
abnormal noise level becomes · Leak in intake system
clear when the engine speed is · Damaged intake system
increased.
Turbocharger
HINT:
· The turbocharger
vibrations are transmitted
to the exhaust pipe,
The chattering sound pitch is lower causing noise and
than the whistling sound pitch. Has resonance.
Chattering sound (metallic sound) a comparatively constant pitch that · The turbocharger
is independent of the engine speed vibrations are transmitted
and vehicle speed. through the exhaust pipe
to the chassis (floor),
causing noise and
resonance in the chassis.
Faults and Symptoms of Diesel Engine Components
Turbocharger system
· Unstable turbocharger turbine shaft
Main fault (interference, seizing, poor balance, etc.)
· High-pitched whistling sound
HINT:
The volume and pitch are proportional to
Symptom the turbocharger speed.
· Metallic sound due to looseness
Intake system
Main fault Leak
Symptom Abnormal noise during intake leak
Transmission gears
Gear noise
HINT:
Symptom The volume and pitch are proportional to the
transmission gear speed.
https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MGDF.html?PUB_TYPE=RM&MODE=1 Page 1 of 13
Print-Toyota Service Information 11/3/17, 4(26 pm
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?
· Ambient temperature
Temperature · Engine temperature (cold, warmed up,
etc.)
· City or highway driving
Road conditions · Uphill or downhill
· Did the noise occur suddenly, or build
gradually?
Noise level · Has the noise gradually been getting
louder?
· Lack of power
Other symptoms · High fuel consumption, etc.
What made the customer determine that the
Noise recognition
sound was a malfunction?
Result:
Proceed to
NEXT
NEXT
2.PERFORM SIMULATION TEST
2.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.
Result:
Result Proceed to
Abnormal noise generated while idling (ticking or rattling (metallic
A
sound))
Abnormal noise generated while driving B
https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MGDF.html?PUB_TYPE=RM&MODE=1 Page 2 of 13
Print-Toyota Service Information 11/3/17, 4(26 pm
3.CHECK FOR NOISE FROM SOURCE OTHER THAN TURBOCHARGER
8.CONFIRM NOISE SOURCE (FROM TURBOCHARGER SUB-ASSEMBLY OR NOT)
3.CHECK FOR NOISE FROM SOURCE OTHER THAN TURBOCHARGER
a. Check for the noise source with a sound scope.
b. 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).
c. Sometimes gear noise may be mistaken for turbocharger noise. For gear noise, pay attention to the gear
inside the engine and transmission gear.
d. 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.
e. Check whether the noise described by the customer occurs.
Result:
Result Proceed to
Abnormal noise generated from turbocharger A
Abnormal noise generated from parts other than turbocharger B
4.CHECK TURBOCHARGER SUB-ASSEMBLY
5.CHECK FOR NOISE FROM SOURCE OTHER THAN TURBOCHARGER (PROCEDURE 5)
4.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:
Result Proceed to
No damage or interference A
Damage or interference exists B
END (CAUSE CHECK EXCEPT THE TURBO CHARGER)
https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MGDF.html?PUB_TYPE=RM&MODE=1 Page 3 of 13
Print-Toyota Service Information 11/3/17, 4(26 pm
REPLACE TURBOCHARGER SUB-ASSEMBLY
Click hereEngine / Hybrid System>1GD-FTV INTAKE / EXHAUST>EXHAUST MANIFOLD W/
TURBOCHARGER>REMOVAL
5.CHECK FOR NOISE FROM SOURCE OTHER THAN TURBOCHARGER (PROCEDURE 5)
a. Check for the noise source.
CAUTION:
When performing this check, make sure that the sound scope, your body, etc., do not get caught on the
V-belt.
HINT:
· The source of the noise is not the turbocharger sub-assembly, but a part other than the
turbocharger sub-assembly (e.g. a part inside the engine, transmission, or vacuum pump).
· Sometimes gear noise may be mistaken for turbocharger noise.
For gear noise, pay attention to the gear inside the engine and transmission gear.
· 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.
Result:
Proceed to
NEXT
NEXT
6.REPLACE THE PARTS DETECTED IN PROCEDURE 5
6.REPLACE THE PARTS DETECTED IN PROCEDURE 5
a. Replace the parts detected in procedure 5 as the noise source.
Result:
Proceed to
NEXT
NEXT
7.CONFIRM WHETHER THE NOISE PROBLEM HAS BEEN SUCCESSFULLY SOLVED
7.CONFIRM WHETHER THE NOISE PROBLEM HAS BEEN SUCCESSFULLY SOLVED
a. Check whether the noise problem has been successfully solved.
Result:
Proceed to
NEXT
https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MGDF.html?PUB_TYPE=RM&MODE=1 Page 4 of 13
Print-Toyota Service Information 11/3/17, 4(26 pm
NEXT
END
8.CONFIRM NOISE SOURCE (FROM TURBOCHARGER SUB-ASSEMBLY OR NOT)
a. Connect the GTS to the DLC3.
b. Start the engine and warm it up.
c. Turn the GTS on.
d. Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the VN Turbo Open.
Powertrain > Engine and ECT > Active Test
Tester Display
Activate the VN Turbo Open
Execute
e. Perform the Active Test under the conditions* from the time the noise occurred described by the customer
and compare the noise to the noise heard when not performing the Active Test and check if the noise is
reduced.
HINT:
*: Some examples of conditions are idling, racing the engine and driving at full throttle.
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:
· By performing Activate the VN Turbo Open Active Test, the variable nozzle of the turbocharger
sub-assembly becomes fully open regardless of the engine condition, and the turbocharger speed
does not increase.
· If the turbocharger sub-assembly is the cause of the noise, the noise will be reduced when
Activate the VN Turbo Open Active Test is performed because turbocharger speed does not
increase.
9.PERFORM SIMULATION TEST
5.CHECK FOR NOISE FROM SOURCE OTHER THAN TURBOCHARGER (PROCEDURE 5)
9.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.
https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MGDF.html?PUB_TYPE=RM&MODE=1 Page 5 of 13
Print-Toyota Service Information 11/3/17, 4(26 pm
b. If an abnormal noise is confirmed, determine which system emits it.
Result:
Result Proceed to
Noise occurs (squealing (metallic sound) when driving) A
Noise occurs (hissing (airflow sound) when driving) B
Noise occurs (whistling or foghorn-like (airflow sound) during acceleration) C
Noise occurs (whistling (airflow sound) during deceleration) D
10.CHECK TURBOCHARGER SUB-ASSEMBLY
15.CHECK TURBOCHARGER SUB-ASSEMBLY
21.CHECK TURBOCHARGER SUB-ASSEMBLY
26.CHECK GEAR NOISE
10.CHECK TURBOCHARGER SUB-ASSEMBLY
a. Check that the turbine shaft rotates smoothly, without catching.
Click hereEngine / Hybrid System>1GD-FTV INTAKE / EXHAUST>EXHAUST MANIFOLD W/
TURBOCHARGER>INSPECTION
b. Check for loose turbine mounting nuts and for axial play in the turbine shaft.
Click hereEngine / Hybrid System>1GD-FTV INTAKE / EXHAUST>EXHAUST MANIFOLD W/
TURBOCHARGER>INSPECTION
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:
Result Proceed to
No turbine shaft malfunction A
Turbine shaft malfunction B
11.CHECK TURBOCHARGER SUB-ASSEMBLY
REPLACE TURBOCHARGER SUB-ASSEMBLY
https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MGDF.html?PUB_TYPE=RM&MODE=1 Page 6 of 13
Print-Toyota Service Information 11/3/17, 4(26 pm
Click hereEngine / Hybrid System>1GD-FTV INTAKE / EXHAUST>EXHAUST MANIFOLD W/
TURBOCHARGER>REMOVAL
11.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:
Result Proceed to
Damage or interference exists A
No damage or interference B
12.REPLACE TURBOCHARGER SUB-ASSEMBLY
14.CHECK TURBOCHARGER SUB-ASSEMBLY
12.REPLACE TURBOCHARGER SUB-ASSEMBLY
a. Replace the turbocharger sub-assembly.
Click hereEngine / Hybrid System>1GD-FTV INTAKE / EXHAUST>EXHAUST MANIFOLD W/
TURBOCHARGER>REMOVAL
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 TURBOCHARGER SUB-ASSEMBLY
https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MGDF.html?PUB_TYPE=RM&MODE=1 Page 7 of 13
Print-Toyota Service Information 11/3/17, 4(26 pm
a. Check for interference between the turbine wheel and the turbine housing.
Result:
Result Proceed to
No damage or interference* A
Damage or interference exists B
HINT:
*: Replace the turbocharger sub-assembly, as the abnormal noise may have been caused by interference
between the turbine blades and housing.
REPLACE TURBOCHARGER SUB-ASSEMBLY
Click hereEngine / Hybrid System>1GD-FTV INTAKE / EXHAUST>EXHAUST MANIFOLD W/
TURBOCHARGER>REMOVAL
REPLACE TURBOCHARGER SUB-ASSEMBLY
Click hereEngine / Hybrid System>1GD-FTV INTAKE / EXHAUST>EXHAUST MANIFOLD W/
TURBOCHARGER>REMOVAL
15.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.
https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MGDF.html?PUB_TYPE=RM&MODE=1 Page 8 of 13
Print-Toyota Service Information 11/3/17, 4(26 pm
Result:
Result Proceed to
No adhering soot or an oil* A
Soot adhering around the turbine housing, flange, or exhaust pipe clamp
B
(A in the illustration)
Oil leak from the contact surface between the compressor housing and
C
bearing housing (B in the illustration)
Oil adhering to the compressor flange (C in the illustration) D
HINT:
*: Since abnormal noise may be the result of airflow noise from the blades, replace the turbocharger sub-
assembly.
16.REPLACE TURBOCHARGER SUB-ASSEMBLY
18.CHECK EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
REPLACE TURBOCHARGER SUB-ASSEMBLY
Click hereEngine / Hybrid System>1GD-FTV INTAKE / EXHAUST>EXHAUST MANIFOLD W/
TURBOCHARGER>REMOVAL
REPLACE GASKET
16.REPLACE TURBOCHARGER SUB-ASSEMBLY
a. Replace the turbocharger sub-assembly.
Click hereEngine / Hybrid System>1GD-FTV INTAKE / EXHAUST>EXHAUST MANIFOLD W/
TURBOCHARGER>REMOVAL
Result:
Proceed to
NEXT
NEXT
17.PERFORM SIMULATION TEST
17.PERFORM SIMULATION TEST
a. Check that the abnormal noise has disappeared.
Result:
Proceed to
https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MGDF.html?PUB_TYPE=RM&MODE=1 Page 9 of 13
Print-Toyota Service Information 11/3/17, 4(26 pm
NEXT
NEXT
END
18.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 with valve housing sub-assembly.
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-
B
assembly mounting surface
Deformation or cracks on the turbine with valve housing sub-assembly
C
mounting surface
19.REPLACE EXHAUST PIPE CLAMP AND GASKET
REPLACE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
Click hereEngine / Hybrid System>1GD-FTV EMISSION CONTROL>MONOLITHIC
CONVERTER(w/o DPF)>REMOVAL
REPLACE TURBOCHARGER SUB-ASSEMBLY
Click hereEngine / Hybrid System>1GD-FTV INTAKE / EXHAUST>EXHAUST MANIFOLD W/
TURBOCHARGER>REMOVAL
19.REPLACE EXHAUST PIPE CLAMP AND GASKET
a. Replace the exhaust pipe clamp and the gasket.
Result:
Proceed to
NEXT
NEXT
https://toyotamanuals.com.au/docs/hilux-service-repair-manual…anual/repair/contents/RM100000000MGDF.html?PUB_TYPE=RM&MODE=1 Page 10 of 13
Print-Toyota Service Information 11/3/17, 4(26 pm
20.PERFORM SIMULATION TEST
20.PERFORM SIMULATION TEST
a. Check that the abnormal noise has disappeared.
Result:
Proceed to
NEXT
NEXT
END
21.CHECK TURBOCHARGER SUB-ASSEMBLY
a. Check that the turbine shaft rotates smoothly, without catching.
Click hereEngine / Hybrid System>1GD-FTV INTAKE / EXHAUST>EXHAUST MANIFOLD W/
TURBOCHARGER>INSPECTION
b. Check for loose turbine mounting nuts and for axial play in the turbine shaft.
Click hereEngine / Hybrid System>1GD-FTV INTAKE / EXHAUST>EXHAUST MANIFOLD W/
TURBOCHARGER>INSPECTION
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:
Result Proceed to
No turbine shaft malfunction A
Turbine shaft malfunction B
22.CHECK TURBOCHARGER SUB-ASSEMBLY
REPLACE TURBOCHARGER SUB-ASSEMBLY
Click hereEngine / Hybrid System>1GD-FTV INTAKE / EXHAUST>EXHAUST MANIFOLD W/
TURBOCHARGER>REMOVAL
22.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 turbocharger sub-assembly and determine if the
https://toyotamanuals.com.au/docs/hilux-service-repair-manual…anual/repair/contents/RM100000000MGDF.html?PUB_TYPE=RM&MODE=1 Page 11 of 13
Print-Toyota Service Information 11/3/17, 4(26 pm
noise improved.
Result:
Result Proceed to
Damage or interference exists A
No damage or interference B
23.REPLACE TURBOCHARGER SUB-ASSEMBLY
25.CHECK TURBOCHARGER SUB-ASSEMBLY
23.REPLACE TURBOCHARGER SUB-ASSEMBLY
a. Replace the turbocharger sub-assembly.
Click hereEngine / Hybrid System>1GD-FTV INTAKE / EXHAUST>EXHAUST MANIFOLD W/
TURBOCHARGER>REMOVAL
Result:
Proceed to
NEXT
NEXT
24.PERFORM SIMULATION TEST
24.PERFORM SIMULATION TEST
a. Check that the abnormal noise has disappeared.
Result:
Proceed to
NEXT
NEXT
END
25.CHECK TURBOCHARGER SUB-ASSEMBLY
a. Check for interference between the turbine wheel and the turbine housing.
Result:
Result Proceed to
No damage or interference* A
Damage or interference exists B
https://toyotamanuals.com.au/docs/hilux-service-repair-manual…anual/repair/contents/RM100000000MGDF.html?PUB_TYPE=RM&MODE=1 Page 12 of 13
Print-Toyota Service Information 11/3/17, 4(26 pm
HINT:
*: Replace the turbocharger sub-assembly, as the abnormal noise may have been caused by loss of rotational
balance and deterioration over time.
REPLACE TURBOCHARGER SUB-ASSEMBLY
Click hereEngine / Hybrid System>1GD-FTV INTAKE / EXHAUST>EXHAUST MANIFOLD W/
TURBOCHARGER>REMOVAL
REPLACE TURBOCHARGER SUB-ASSEMBLY
Click hereEngine / Hybrid System>1GD-FTV INTAKE / EXHAUST>EXHAUST MANIFOLD W/
TURBOCHARGER>REMOVAL
26.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
© 2012 TOYOTA MOTOR CORPORATION. All Rights Reserved.
https://toyotamanuals.com.au/docs/hilux-service-repair-manual…anual/repair/contents/RM100000000MGDF.html?PUB_TYPE=RM&MODE=1 Page 13 of 13
