D4D 2.2 Turbo Dead?

[Philthy Pierre]

Hi all,

I've had this 55 plate T-Spirit for 2.5 years now and have (until Tuesday morning) been delighted with it's performance and economy.

Most of my driving is motorway, and with cruise control I've been getting 700 miles out of a tank.

Going over to work Monday night I thought I heard a slight clonk, or bang, but could've been my imagination. I thought the car was a bit sluggish on the last couple of hundred yards of the trip.

Setting off home though, the thing seemed to have no power over about 2000rpm, then the engine fault, VSC and TRC lights all came on. Stopped, switched off, waited ten min, then started again, but the lights and problem remained.

When I got home, I poked about and found the hose from the air filter to the turbo was loose. It was as if the turbo end had grown, and could no longer fit snuggly round the turbo case. A bit of work adding extra diameter to the turbo casing got a tight fit again, but no change in symptom.

Later in the day I got an OBD (elm327) box to read the P0400 code which wouldn't go away permanently until I used the forum guide to strip and clean the EGR valve and manifold. Before cleaning, I could see the valve was stuck slightly open.

Q1. to check it's operation, I watched the movement of the valve while switching the ignition on then off. Switching on, the valve moved a couple of millimeters then returned very quickly. Switching off, it did the same, but repeated the move and return I think 5 times. Is this normal?

Reassembled everything and tried again, but still no power above 2000, and revs out at 3500rpm. Suspect turbo.

Watched manifold pressure on the OBD program, and it never rises above ambient, usually below, so I think that confirms no turbo boost.

Using a small mirror and angled tool I could see the turbo could be turned, but was definitely not free spinning. Briefly running the engine with the inlet pipe removed, I could see the turbo turning but definitely not quickly, could have been the inducted air turning it I suppose.

Finally, I've just had the Battery disconnected for 20 min to see if the ECU can learn how to run the turbo again, but still no joy although I can hear what I used to think was the turbo spinning.

So. Is there anything else I could do to diagnose the failure?

Does the vacuum thingy on the turbo lift to open the wastegate and stop spin, or to close it?

Can anyone recommend a turbo supplier (Genuine Toyota may be nice, but £1500 is too ouch)?

Any other ideas?

Cheers,

Philthy Pierre,

[igormus]

hello mate

- total millage

- 1st/2nd owner ?

- air filter last changed date ?

- ditto for fuel filter?

- age of car

- EGR - -have you stripped it down and cleaned well?

- SCV - check with both resistance and compare with limits. If minor diference is available -- just have them changed;

- turbo - undo suction hose from compressor side. Hold the inducer fixing nut and try to push rotor on its axis to understand whether thrust bearing has died?

besides using the same method check rotor in radial direction to evaluate condition of both bearings (support bearing)--rotation must be an easy subject all bearings are in order and opposite.

- engine starting --- your observation -- good or not?

- tail pipe -- does it have a ply of carbon inside?

Check and come back

Cheers/Igor

[Philthy Pierre]

- total millage === 106000

- 1st/2nd owner ? === second owner, was fleet car

- air filter last changed date ? === about 2 months / 4000 miles ago (hose was good fit then)

- ditto for fuel filter? === as air filter

- age of car === 5½ years

- EGR - -have you stripped it down and cleaned well? === I think so, taking off the solenoid I could push the valve fully open and it would close completely

- SCV - check with both resistance and compare with limits. If minor diference is available -- just have them changed; === upper (pink) 2.3Ω, lower (grey) 1560Ω! New ones on order

- turbo - undo suction hose from compressor side. Hold the inducer fixing nut and try to push rotor on its axis to understand whether thrust bearing has died?

besides using the same method check rotor in radial direction to evaluate condition of both bearings (support bearing)--rotation must be an easy subject all bearings are in order and opposite. === I can't get to the nut directly, the best I've managed is to get a socket & ratchet onto it. I can turn the turbo quite easily, but it isn't free spinning.

- engine starting --- your observation -- good or not? === Starting is just as good as ever, no smoke or hesitation.

- tail pipe -- does it have a ply of carbon inside? === There is some carbon inside, not a thick layer of it though

Check and come back

Cheers/Igor

Extra info, in case it's relevant.

Manifold pressure at idle, 22inHg, on acceleration drops to about 16inHg

Fuel pressure at idle about 7000psi, above 2000rpm about 10000psi

Commanded EGR at idle about 20% on acceleration 0%

EGR error at idle from -3% to +3% on acceleration 0%

Thanks for the help, it is GREATLY appreciated

Assuming the SCV resistance is bad, I'll report how the replacements do....

[igormus]

- total millage === 106000

- 1st/2nd owner ? === second owner, was fleet car

- air filter last changed date ? === about 2 months / 4000 miles ago (hose was good fit then)

- ditto for fuel filter? === as air filter

- age of car === 5½ years

- EGR - -have you stripped it down and cleaned well? === I think so, taking off the solenoid I could push the valve fully open and it would close completely

- SCV - check with both resistance and compare with limits. If minor diference is available -- just have them changed; === upper (pink) 2.3Ω, lower (grey) 1560Ω! New ones on order

- turbo - undo suction hose from compressor side. Hold the inducer fixing nut and try to push rotor on its axis to understand whether thrust bearing has died?

besides using the same method check rotor in radial direction to evaluate condition of both bearings (support bearing)--rotation must be an easy subject all bearings are in order and opposite. === I can't get to the nut directly, the best I've managed is to get a socket & ratchet onto it. I can turn the turbo quite easily, but it isn't free spinning.

- engine starting --- your observation -- good or not? === Starting is just as good as ever, no smoke or hesitation.

- tail pipe -- does it have a ply of carbon inside? === There is some carbon inside, not a thick layer of it though

Check and come back

Cheers/Igor

Extra info, in case it's relevant.

Manifold pressure at idle, 22inHg, on acceleration drops to about 16inHg

Fuel pressure at idle about 7000psi, above 2000rpm about 10000psi

Commanded EGR at idle about 20% on acceleration 0%

EGR error at idle from -3% to +3% on acceleration 0%

Thanks for the help, it is GREATLY appreciated

Assuming the SCV resistance is bad, I'll report how the replacements do....

hello again

basing on the records typed by you -- I can point on the following:

- SCV --possible reason

- overfueling due to poor injection ----> as the proof -- you feel sluggish performance by 2000 rpm ---- physically what goes on -- a cycle portion of diesel is more than should be and this excess portion is being burnt on the expansion stroke having braked other cylinders. 106k is the time to calibrate injectors.

- air inside an injection circuit.

As to turbo -- as vissible it is not guilty this time.

Check and revert

Cheers/igor

[Philthy Pierre]

Well, I'm celebrating :)

Struggling up the long motorway hill to Yorkshire, suddenly everything behind me disappeared in a cloud of smoke and power returned!

I had another look at the turbo this morning, and it spins very freely now, so it really wasn't providing boost. Time will tell whether the bearings are damaged, or whether something got in through the loose hose.

Igormus, I'll still be changing the SCVs and follow your advice about getting the injectors cleaned/calibrated.

Also, I'll try to post anything I can measure when it's running well. Maybe we can collect enough information to make a symptom-fix guide?

Cheers,

[igormus]

Well, I'm celebrating :)

Struggling up the long motorway hill to Yorkshire, suddenly everything behind me disappeared in a cloud of smoke and power returned!

I had another look at the turbo this morning, and it spins very freely now, so it really wasn't providing boost. Time will tell whether the bearings are damaged, or whether something got in through the loose hose.

Igormus, I'll still be changing the SCVs and follow your advice about getting the injectors cleaned/calibrated.

Also, I'll try to post anything I can measure when it's running well. Maybe we can collect enough information to make a symptom-fix guide?

Cheers,

hello mate

ok you're on the right way -- as far as I caught you claimed on the turbo shaft rotation easiness.

I could imagine this might be like this cos of poor injection and accumulating of carbon deposits. I suggest a simple using od an additives will burn this carbon out and enable turbo be in order. Now you should test all injectors as they are guilty in your case.

Good luck + do not forget to hang as many photos as possible -- step by step -- this will help to anothers looking for a ring-buoy.

Cheers/Igor