TECHNICAL NOTE 3419A XXXX

DIESEL INJECTION TURBOCHARGER FAULT FINDING ASSISTANCE

This Technical Note deals with all turbocharged diesel injection engines 77 11 295 742
The repair methods given by the manufacturer in this document are based on the technical specifications current when it was prepared. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed.

APRIL 2000
All copyrights reserved by Renault.

EDITION ANGLAISE

Reproduction or translation, in part or in full, of this document or use of the service part reference numbering system is forbidden without the prior written authority of Renault.

RENAULT 2000

DIESEL INJECTION 113 Fault finding - Introduction

NOTES

13

Carry out a conformity check on the injection system, engine management system and engine using the fault finding tool (see relevant fault finding sheets). NOTE: the turbocharger is very rarely the source of a lack of engine performance.

13-1

DIESEL INJECTION Turbocharger fault finding assistance

The engine lacks power despite normal consumption and exhaust emissions (turbo) Problem on the accelerator control. Check that the stop position is obtained with full pedal depression (problem with the thickness of the carpet/mat) and adjust the accelerator cable. Does the fault persist after this operation? yes Check the condition of the air filter and replace if necessary. Does the problem persist after this operation? yes Check the turbocharging pressure. Is the pressure correct? no Incorrect sealing of the inlet circuit. Check the air filter and the air/air exchanger pipes. Does the fault persist after this check? yes yes Faulty turbocharger. Replace the turbocharger: no operation is possible on the turbocharger or the load regulator (except T2). Does the fault persist after replacement?

13

no

End

no

End

no End

yes Pipe between the manifold and the flow corrector disconnected. Does the fault persist after refitting? yes no

no End

End Venting pipe under the flow corrector diaphragm blocked. Does the fault persist after repair? yes Faulty supply circuit. Check the supply and return pipes, conformity of the filler cap, venting and cored screws on the pump. Does the fault persist after checking/replacing? yes

no

End

no

End

13-2

DIESEL INJECTION Turbocharger fault finding assistance

A
The engine lacks power despite normal consumption and exhaust emissions (turbo) (continued) no

13

Perform a test without filler cap. Does the fault persist? yes Check the loss of pressure in the circuit. Measure the value of the vacuum pressure at the filter outlet on the pump side. Is the vacuum pressure > 0.2 bar? yes Measure the value of the vacuum pressure at the filter inlet. Is the value > 0.1 bar? yes Change the fuel filter. Fit only an original cartridge. Does the fault persist after replacement? no End

Fit an approved cap. Does the fault persist after this operation?

no

End

yes

no

no

Check the upstream circuit. Does the fault persist after this operation?

no

yes

End

yes

Check the circuits. Does the fault persist?

no End

yes Discharge pipes crushed at the connections. Check the condition of the internal diameter of the tubes. Replace the faulty parts. Does the problem persist? yes Check the injection pump and distribution timing. Does the fault persist after checking/adjusting? yes The injection pump is incorrectly adjusted. Send it to a Renault Injection Centre.

no

End

no

End

13-3

DIESEL INJECTION Turbocharger fault finding assistance

13

The engine lacks power and there is abnormal consumption and exhaust emissions (turbo) Check the condition of the air filter and replace if necessary. Does the problem persist after this operation? yes Change the fuel filter. Fit only an original cartridge. Does the fault persist after replacement? yes Check the conformity and condition of the injectors (calibration/atomisation...). Does the fault persist after checking and possible replacement? yes Check the turbocharging pressure. Is the pressure correct? no Incorrect sealing of the inlet circuit. Check the air filter and the air/air exchanger pipes. Does the fault persist after this check? yes yes Faulty turbocharger. Replace the turbocharger: no operation is possible on the turbocharger or the load regulator (except T2). Does the fault persist after replacement?

no

End

no

End

no

End

no End

yes Pipe between the manifold and the flow corrector disconnected. Does the fault persist after refitting? yes no

no

End

End Venting pipe under the flow manifold diaphragm blocked. Does the fault persist after repair? yes

no

End

13-4

DIESEL INJECTION Turbocharger fault finding assistance

13

The engine lacks power and there is abnormal consumption and exhaust emissions (turbo) (continued)

Valves adjusted incorrectly. Check and adjust the valve clearances. Does the fault persist after this operation? yes Incorrect timing adjustment. Check the timing adjustment. Does the fault persist after this operation? yes Check the injection pump timing. Does the fault persist after this operation? yes Insufficient engine compression. Check the engine compression. Is it greater than 25 bar? yes Partially clogged exhaust. Check the exhaust circuit. Does the fault persist after this operation? yes no

no

End

no

End

no

End

no

Retune the engine. Does the fault persist after this operation? yes

no

End

End Engine operating temperature too low. Check the cooling circuit (thermostat). Does the fault persist after checking/ replacing? yes no The injection pump is incorrectly adjusted. Send it to a Renault Injection Centre. End

13-5

DIESEL INJECTION Turbocharger fault finding assistance

The engine emits blue exhaust fumes

13

Engine running (when cold)

Are there blue exhaust fumes at idle speed and with unladen acceleration (engine cold)?

Engine running (when hot)

Are there blue exhaust fumes at idle speed and with unladen acceleration (engine hot)? yes Engine stationary.

no

The turbocharger is not the fault. Perform fault finding on the other engine functions (pre-postheating, injection...)

Is the engine oil level greater than the maximum? no Does the engine consume too much oil (according to manufacturer's procedure)? yes

yes

Correct the oil level

no

The turbocharger is not the fault. Perform fault finding on the other engine functions.

Is the air filter clogged?

yes

Replace the filter element or clean the air filter.

no

13-6

DIESEL INJECTION Turbocharger fault finding assistance

A
The engine emits blue exhaust fumes (continued)

13

Check the air supply circuit from the air filter to the turbocharger and from the turbocharger to the engine (tightness, conformity...)

Engine running

Is the air inlet circuit between the turbocharger and the engine tight? yes Are the air ducts deformed or pinched, are they deformed or pinched with unladen acceleration? no Engine stationary.

no

Replace the faulty parts or eliminate the leak

yes

Replace the air ducts concerned

(*)

Note: It is normal to find traces of oil at the turbocharger inlet and outlet, as the air entering the compressor contains oil from the engine rebreathing circuit

Is the air duct between the turbocharger and the exchanger (or between the turbocharger and the engine, if there is no exchanger) abnormally greasy (*) ? yes

no

Is the air duct from the air filter greasy at the turbocharger inlet?

yes

Check the crankcase gas recirculation system (oil decanter, crankcase vent, ...) and the gas pressure in the cylinder block.

no Is the oil return pipe from the turbocharger blocked, deformed or pinched? no Remove the turbocharger yes Replace the turbocharger oil return pipe

13-7

DIESEL INJECTION Turbocharger fault finding assistance

The engine emits blue exhaust fumes (continued)

13
B

Remove the turbocharger

Are there traces of oil in the engine exhaust manifold and in the turbocharger inlet pipe (exhaust gas inlet to the turbocharger)? no Are there traces of oil at the turbocharger outlet, on the exhaust pipe side (exhaust bend inlet or exhaust pipe inlet) yes Is the oil return pipe from the turbocharger blocked or pinched? no Replace the turbocharger

yes

The turbocharger is not the fault. The oil is coming from the engine. Check the engine (piston segmentation, valve rod, gas pressure in the cylinder block, ...)

no

The turbocharger is not the fault. Check the engine (piston segmentation, valve rods, gas pressure in the cylinder block, ...) and the injection equipment

yes

Correct to default

13-8

DIESEL INJECTION Turbocharger fault finding assistance

The engine produces black exhaust fumes

13

Engine stationary.

Is the air filter clogged?

yes

Replace the filter element or clean the air filter.

no Check: the air supply circuit from the air filter to the turbocharger and from the turbocharger to the engine (tighness, conformity...) the connection and tightness of the connections on the flow corrector control circuit (injection pump).

Engine running and vehicle stationary

Do the air ducts deform or pinch with unladen acceleration? no Engine running and vehicle moving

yes

Replace the air ducts concerned

Is the turbocharging pressure under load correct?

yes

Check the other components: injection system, diesel supply circuit, engine, exchanger (clogging)

no

13-9

DIESEL INJECTION Turbocharger fault finding assistance

The engine produces black exhaust fumes (continued)

13

Engine running vehicle stationary

Is the air inlet circuit between the turbocharger and the engine tight? yes Is there an exhaust gas leak between the engine and the turbocharger (engine outlet, exhaust manifold, turbine inlet)? no Is the vehicle exhaust system after the turbocharger blocked or partially blocked? no Engine stationary.

no

Replace the faulty parts or eliminate the leak

yes

Eliminate the leak

yes

Replace any faulty parts.

Are the valve clearances and compression correct? Is the timing adjusted correctly?

no

Correct to default

yes

13-10

DIESEL INJECTION Turbocharger fault finding assistance

The engine produces black exhaust fumes (continued)

13

Is the injection system correct? Are the connections correct (diesel circuit, flow corrector)? Are the adjustments correct (static adjustment, flow and flow corrector adjustment, advance adjustment)? yes Remove the turbocharger

no

Correct to default

Replace the turbocharger

13-11

DIESEL INJECTION Turbocharger fault finding assistance

Noise or whistling

13

Engine running (when cold)

Drive with the vehicle in 2nd and 3rd gear at an engine speed of 1700 to 3500 rpm.

Is there a noise from the turbocharger (whistling), which varies with the engine speed when accelerating (engine cold)?

Engine running (when hot)

Drive with the vehicle in 2nd and 3rd gear at an engine speed of 1700 to 3500 rpm.

Is there a noise from the turbocharger (whistling), which varies with the engine speed when accelerating (engine warm)? yes Is the air inlet circuit between the turbocharger and the engine tight? yes Is the air inlet circuit between the air filter and the turbocharger tight?

no

The turbocharger is not the fault.

no

Replace the faulty parts or eliminate the leak

no

Replace the faulty parts or eliminate the leak

yes

13-12

DIESEL INJECTION Turbocharger fault finding assistance

Noise and whistling (continued)

13

Are the air ducts deformed or pinched, are they deformed or pinched with unladen acceleration? no Engine stationary.

yes

Replace the air ducts concerned

Is the air filter clogged?

yes

Replace the filter element or clean the air filter.

no no

Is the exhaust pipe correct?

Correct it to return it to conformity

yes Engine running

Is there an exhaust gas leak between the engine and the turbocharger (engine outlet, exhaust manifold, turbine inlet)? no Is there an exhaust gas leak in the vehicle exhaust system after the turbocharger? no Remove the turbocharger

yes

Eliminate the leak

yes

Eliminate the leak

Replace the turbocharger

13-13

DIESEL INJECTION Turbocharger fault finding assistance

Air breathing (turbocharger)

13

Leak in the turbocharging air circuit. Check the tightening of the air/air exchanger pipes and the exhaust and inlet manifolds. Does the fault persist after this operation? yes Leak in injector seals. Replace any faulty seals. Does the fault persist after replacement? yes Leak in a preheating plug. Tighten the plug correctly or replace it if necessary. Does the fault persist after this operation? yes Leak in cylinder head gasket. Replace the cylinder head gasket and check the mating surfaces.

no

End

no

End

no

End

13-14