Fact Sheet 8 - Toyota Hilux/Prado/HiAce 1KD-FTV 3.0TD trouble shooting/must do's and stepper motor instructions

Application: Toyota Hilux / Prado / HiAce 1KD-FTV & 1GD-FTV 2005>

Turbochargers are very reliable: less than 1% of turbo’s fail due to a manufacturing fault with the turbo itself, most issues are the result of other engine related factors.

IT IS CRITICAL THE FOLLOWING ADVICE IS TAKEN INTO CONSIDERATION:

Before Replacing the Turbocharger on the above applications:

1. Visually inspect the inlet manifold for signs of carbon and soot build up, in the ports or on the secondary butterflies, if carbon is present remove the inlet manifold and physically clean all components fully, failure to do so could cause premature failure of the turbocharger and may void warranty. Loose carbon can cause turbine damage as indicated below (image #1).

2. Check the vacuum operation of the secondary butterflies after cleaning and ensure they work to OEM specification, if they do not replace with genuine OEM product.

3. Visually inspect the exhaust manifold for signs of carbon and soot build up, if carbon is present remove the exhaust manifold and fully clean, removing all contamination, failure to do so could cause premature failure of the turbocharger and may void warranty. Loose carbon can cause turbine damage as indicated (image #1).

4. Inspect the condition of the upper engine (head) for signs of sludging of the oil (image #3), this is very common and needs to be fully cleaned to ensure no contamination can cause premature turbocharger failure.

5. Remove and inspect all fuel injectors and seals to ensure no leakage in occurring as this can be the cause of carbon and soot deposits due to unburnt fuel being deposited over time in the gas flow path. If the vehicle has been tuned or has a fuel controller chip ensure the fuel delivery rate in correct to the turbocharger boost and flow parameters, failure to match these can cause premature turbocharger failure and may void warranty.

6. Check the condition of the Map sensor filter, pay attention to any case cracking and internal blockages, we recommend this be replaced 100% of the time with a turbocharger replacement.

7. Remove and clean the manifold pressure sensor and mass airflow sensor and scan test to ensure they are working correctly, if they fail the test replace before running the vehicle as over boost from a faulty signal can fail the turbocharger and void warranty.

8. Remove, clean and inspect all intercooler and intake hoses, if the initial turbocharger failure was pumping oil into the intercooler this must be remove cleaned and pressure tested.

9. Remove and clean the EGR valve and ensure the valve is operating freely, if the vehicle has had an EGR delete fitted it is recommended it be returned to OEM specification.

10. Inspect the wiring harness and connections for the stepper motor, especially if the vehicle has been in fine dust/sand environment or through water crossings. Should you determine a stepper motor needs replacing GCG can undertake this service off vehicle or you can follow the advice below.

11. Inspect the exhaust system and check for restrictions or blockages, change in diameters of the exhaust whereby a custom-made system has been fitted can cause flow issues and create back pressure issues inside the turbocharger and its operation.

12. Follow Turbo Pros's universal turbocharger fitting guide as supplied with this Fact Sheet

13. Consider installing an Oil Catch Can as a preventative maintenance unit.

  

Replacement of VNT Stepper Motor Controller:

1. Inspect stepper motor connectors for damage or sign of connection shorting issue, if damaged replace with new part.

2. Inspect and test stepper motor wiring harness for continuity between terminals, if continuity test fails replace with new part.

3. With all electrical connectors disconnected, remove e-clip holding the stepper motor control arm from the drive arm attached to the turbocharger, slide off the arm, remove mounting bolts (2) for the entire stepper motor and the stepper motor is free.

4. Visually inspect the turbocharger impellor for damage or scuffing on the housing(s), if issues are evident remove turbocharger and send for service or replace with a new turbocharger.

5. Without the stepper motor on the turbocharger, grab the drive arm on the turbocharger and move up and down to ensure free and easy movement, if the drive arm is sticky, notchy, or seized in operation due to carbon/soot build up or water contamination causing rusting, remove the turbocharger and send for service or 100% replace. This may cause a new stepper motor to burn out when re-installed due to resistance in operation.

6. Inspect and test MAF Meter, if damaged replace with new unit.

7. Inspect and ensure the EGR is clean and operational, if stuck open or clogged with carbon/soot deposit’s, clean or replace with new.

8. Inspect and Test Manifold Absolute Pressure Sensor, if this fails replace with a new unit.

9. Inspect all exhaust gasket connections to ensure no leak or gasket damage is evident, if issues are found either replace the gasket, studs and nuts or re-torque nuts to ensure complete seal.

10.Re-test operation of the turbocharger and stepper motor controller with the Scan Tool for 100% operation.

 

Turbo Pros supplies brand new replacement turbochargers, these are made to the highest quality standard. Though we confidently guarantee them, our standard warranty does not cover turbocharger (s) or component(s) failure caused by issue(s) raised above.