[Kennekam]

I have a 2005 LWB 3.2 DiD.

At about 120,000kms the engine light started to come on when accelerating and there was a loss of power. The agents cleaned the waste-gate and all was well.

However, when accelerating under load, there was a noise coming from the engine which is difficult to describe but similar to having birds running on a corrugated roof.

Now, at 170,000kms, the problem is back. The engine light comes on and power is cut until you lift the foot off the accelerator. At first it only happened when the engine was cold, no it happens every time I accelerate up a hill.

The error code says it is a turbo over-boost problem. The hoses have been checked and cleaned. The waste-gate has been cleaned. The sensor has been cleaned. Now the service center I use wants to remove the turbo for inspection. I trust these guys explicitly, so I presume it is the next logical step.

What I would like some help with is the following:

1. At 170k, what else should be be done to the turbo while it is off? An overhaul?

2. Are there any other parts around the turbo that should be inspected or replaced at this mileage?

[Nick Gibson]

I did the 2mm wastegate spacer mod on my Pajero and it does exactly as you describe, under heavy acceleration it lights up the CEL and cuts power, I need to remove them again.

Check on your wastegate actuator that the little hose connecting it to the turbo is correctly fitted and not perished or broken or blocked. This hose pressurises the actuator to open the wastegate when the turbo boost reaches a specific pressure of about 1.6bar. If it doesn't do that the boost pressure will rise higher and cause a CEL event. If that hose is fine your wastegate actuator is probably not working properly by not opening at the correct boost pressure, you need to have the actuator checked for opening pressure.

By all accounts your turbo seems to be working correctly, just the wastegate causing over boost issues somehow.

CEL= check engine light.

[Nick Gibson]

Solved my problem here:
https://www.pajeroclub.co.za/forum/view ... &start=489

Look my post on the sticky actuator.

[Kennekam]

Solved my problem here:
https://www.pajeroclub.co.za/forum/view ... &start=489

Look my post on the sticky actuator.

Not sure it is the right link...

[Kennekam]

I did the 2mm wastegate spacer mod on my Pajero and it does exactly as you describe, under heavy acceleration it lights up the CEL and cuts power, I need to remove them again.

Check on your wastegate actuator that the little hose connecting it to the turbo is correctly fitted and not perished or broken or blocked. This hose pressurises the actuator to open the wastegate when the turbo boost reaches a specific pressure of about 1.6bar. If it doesn't do that the boost pressure will rise higher and cause a CEL event. If that hose is fine your wastegate actuator is probably not working properly by not opening at the correct boost pressure, you need to have the actuator checked for opening pressure.

By all accounts your turbo seems to be working correctly, just the wastegate causing over boost issues somehow.

CEL= check engine light.

We did check this the last time. My service guy now has the car and reports that the turbo is showing some signs of wear in the bearings and there is blowby, so he suggested we have it overhauled.
At 180k it is a bit early, but then I would rather just get it over and done with.

[Nick Gibson]

Excessive wear on the turbo would lead to under-boost due to less volume of air being pumped by the compressor. This is due to exhaust gasses & air bypassing the compressor and turbine blades due to large clearance between the housing and blades, it will not cause an overboost Check Engine Light condition... Overboost is caused by a faulty/sticky wastegate mechanism by not bypassing enough exhaust gasses past the turbine wheel at the correct manifold pressure.

Question: At what pressure does the actuator open and by how much?
Mine now opens about 2mm at 160kPa and 10mm at 190kpa. These days Mechanics are lazy to repair, they rather just swop parts out until the problem goes away and you foot the bill.

See my post here, hope this link works now:
https://www.pajeroclub.co.za/forum/view ... &start=480

[CATS]

Nick

The link works but goes to the last post which was not yours.
Kennekan, go to post #490 on that thread page 49 to see Nick's post.

CATS

[4ePikanini]

sounds to me like the wastegate actuator diaphragm spring is dud.

[Kennekam]

Got my car back after two weeks. Both the service center and the turbo repair guy was overbooked due to the yearend rush. Fortunately I did not really need the car.

The over boost was caused by worn and sticky bushes on the waste gate. But they picked up that there was runout on the shaft and play in the bearings of the turbo so I told them to go ahead and refurb the turbo while it was off the engine. Might as well as I am at 180k and do not know how the previous owner drove.

Quite a bit of work was done as they were waiting for the turbo to come back. Front and rear disks skimmed, new rear pads, full service with all filters replaced. All new gaskets pipes. The whole lot including the turbo refurbishment came to R15k. Less than I expected given the amount of work required to remove and refit the turbo.

What I do notice is that the car is more responsive and pulls better. Could that be because the turbo was not running true beforehand.? Or is it just my imagination?



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[Kennekam]

O no! The dreaded engine light came on again four times today. When going up a steep hill the gearbox downshifted and the engine light came on with commensurate power loss. This is despite a turbo rebuild in December.
Not sure what to do now....