Electronic actuator - Symptoms of turbine damage. Errors and types of actuator damage

Turbocharger Actuator Error?

Hella electronic actuators. There are several generations of these mechanisms for regulating variable geometry position.

The first was designed using space technology. It contains a ceramic microprocessor that does not change its properties at different temperatures. It can work consistently at -100 and +150 degrees Celsius.

This was a project from the "fat" pre-crisis times of the automotive industry, when engineers could realize their dreams at the expense of their company. Nevertheless, the design passed the test and has worked in some vehicles for over a decade. The weak points, however, are the worm gear and position sensor, which are made of a special plastic containing graphite PPS (Polifenylosulfidum). This allows for reduced friction between the worm gear and potentiometer. The electronic motor often wears out.

In the years after the crisis, cost-cutting began. The electronics were simplified. Mechanical parts underwent almost no changes. In the newest vehicles, the design from the 2000s is still used. However, they have been effectively technologically streamlined for savings and optimization of the production process.

Very rarely, contacts on the boards get damaged, which can immobilize the actuator permanently (damage to the power contact) or cause unstable actuator operation. This results from working conditions and excessive vibration.

What are the symptoms of actuator damage?

Most often, the worm gear and potentiometer wear out. The symptom is excessive play in the actuator lever, which in turn can cause incorrect position of the variable geometry and incorrect boost pressure. Motor wear shows excessive current consumption. It's worth remembering that the resistance of metals changes depending on their temperature, so a proper test under battle conditions can be performed at temperatures above 60-80 degrees. The parameters that we read from the motor will be closest to the actual ones that occur on a running engine.

Electronic Actuator Repair

At first glance, this is not a complicated activity. But like everything, it requires practical knowledge and appropriate tools. Most often, the motor and worm gear are replaced. There is more work involved in replacing the potentiometer, but these are also replaced.

The most important element of this process, in our opinion, is the quality of the components. If we use cheaper worm gears, they will last 3-6 months, wear out, and again the turbine (or the actuator itself) will need to be dismantled and repaired again. We have also seen cases of actuator blocking due to poor quality parts and repairs.

When can't an actuator be repaired?

The newest Hella actuators are often unrepairable. This is caused by several factors:

1. The actuator's construction is non-disassemblable. It is not easy to access the mechanical parts of the actuator without breaking the housing. There are methods for disassembling such actuators, but they are more expensive and time-consuming.
2. Lack of parts for actuators. The newer the car, the newer the type of actuator, and the greater the probability that there are no parts yet for actuator repair.

Both causes described above, in our opinion, are due to the manufacturer's desire to eliminate companies repairing turbochargers. Evidence of this is the fact that companies like Hella have started selling their actuators, which was not the case 3 years ago.

Repair or buy a new replacement?

In the case of some types of actuators, replacements are acceptable. We form our opinion based on actuator tests we conducted and feedback from our customers after a longer period of use.

When it comes to Hella actuators with a worm gear mechanism, we advise against buying a replacement. Below we present arguments for why we have this position:

1. The internal elements of the actuator are different from the original. No possibility to repair this actuator.
2. The worm gear's plastic is of poor quality. Such an actuator will work efficiently for 3-6 months (depending on driving mode and usage conditions). Later, due to excessive play, it will fail.
3. Use of lubricants in worm gears. Contrary to appearances, lubricating substances contribute to faster worm gear wear.