Last Modified: 05-13-2024 6.11:8.1.0 Doc ID: RM10000000255UL
Model Year Start: 2023 Model: GR Corolla Prod Date Range: [09/2022 -           ]
Title: G16E-GTS (ENGINE CONTROL): SFI SYSTEM: Turbocharger Noise; 2023 - 2025 MY GR Corolla [09/2022 -        ]

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

NEXT
NEXT

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.
B

GO TO DTC CHART
A

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 2023 - 2025 MY GR Corolla [09/2022 -        ]; G16E-GTS (ENGINE CONTROL): SFI SYSTEM: INITIALIZATION

A

REPLACE TURBOCHARGER SUB-ASSEMBLY

HINT:

  • If there is a change in abnormal noise when the waste gate valve rod is pushed down, the noise may be a metallic sound from increased rattle due to wear.

    When the waste gate valve rod is pressed down and a change in the abnormal noise occurs, there is a possibility of metallic sounds being caused by wear due to looseness spreading in the waste gate valve actuator assembly, waste gate valve rod and waste gate valve connections wear.

  • When the waste gate valve rod is pressed down and there is no change in noise, there is a possibility of metallic sounds being caused by wear due to looseness spreading in the waste gate valve wear.

C

GO TO STEP 8

D

GO TO STEP 12

E

GO TO STEP 17

B

4.

CHECK TURBOCHARGER SUB-ASSEMBLY

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

Click here 2023 - 2025 MY GR Corolla [09/2022 -        ]; G16E-GTS (INTAKE / EXHAUST): TURBOCHARGER: INSPECTION

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

Click here 2023 - 2025 MY GR Corolla [09/2022 -        ]; G16E-GTS (INTAKE / EXHAUST): 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:

0.20 mm (0.007874 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 2023 - 2025 MY GR Corolla [09/2022 -        ]; G16E-GTS (ENGINE CONTROL): SFI SYSTEM: INITIALIZATION

B

REPLACE TURBOCHARGER SUB-ASSEMBLY

A

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 2023 - 2025 MY GR Corolla [09/2022 -        ]; G16E-GTS (ENGINE CONTROL): SFI SYSTEM: INITIALIZATION

B

REPLACE TURBOCHARGER SUB-ASSEMBLY

A

6.

REPLACE TURBOCHARGER SUB-ASSEMBLY

Click here 2023 - 2025 MY GR Corolla [09/2022 -        ]; G16E-GTS (INTAKE / EXHAUST): TURBOCHARGER: REMOVAL

NEXT

7.

PERFORM SIMULATION TEST

(a) Check that the abnormal noise has disappeared.

NEXT

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 or oil adhering around the V band (A in the illustration)

B

Oil adhering to the compressor flange or hose clamp (B in the illustration)

C

HINT:

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

Click here 2023 - 2025 MY GR Corolla [09/2022 -        ]; G16E-GTS (ENGINE CONTROL): SFI SYSTEM: INITIALIZATION

B

REPLACE TURBOCHARGER SUB-ASSEMBLY

C

GO TO STEP 11

A

9.

REPLACE TURBOCHARGER SUB-ASSEMBLY

Click here 2023 - 2025 MY GR Corolla [09/2022 -        ]; G16E-GTS (INTAKE / EXHAUST): TURBOCHARGER: REMOVAL

NEXT

10.

PERFORM SIMULATION TEST

(a) Check that the abnormal noise has disappeared.

NEXT

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 hose clamp part of compressor outlet, the installation may be incorrect due to loose clamp or defective hose. Check the installation or replace the hose and clamp.
NEXT

END

12.

CHECK TURBOCHARGER SUB-ASSEMBLY

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

Click here 2023 - 2025 MY GR Corolla [09/2022 -        ]; G16E-GTS (INTAKE / EXHAUST): TURBOCHARGER: INSPECTION

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

Click here 2023 - 2025 MY GR Corolla [09/2022 -        ]; G16E-GTS (INTAKE / EXHAUST): 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:

0.20 mm (0.007874 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 2023 - 2025 MY GR Corolla [09/2022 -        ]; G16E-GTS (ENGINE CONTROL): SFI SYSTEM: INITIALIZATION

B

REPLACE TURBOCHARGER SUB-ASSEMBLY

A

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 2023 - 2025 MY GR Corolla [09/2022 -        ]; G16E-GTS (ENGINE CONTROL): SFI SYSTEM: INITIALIZATION

B

REPLACE TURBOCHARGER SUB-ASSEMBLY

A

14.

REPLACE TURBOCHARGER SUB-ASSEMBLY

Click here 2023 - 2025 MY GR Corolla [09/2022 -        ]; G16E-GTS (INTAKE / EXHAUST): TURBOCHARGER: REMOVAL

NEXT

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
A

END
B

16.

CHECK GEAR NOISE

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

NEXT

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.

NEXT

END