Diesel Turbo System Failure: Boost & Power Loss Fix

Had a similar issue with my 2012 Chevy Aveo diesel. As someone with some hands-on experience working on turbo systems, those symptoms instantly reminded me of what I dealt with. The boost sensor readings were all over the place, and the car showed identical issues, especially that characteristic power loss and whistling noise. After some back and forth with my workshop, they found a damaged wire connection to the boost pressure sensor. Apparently, engine vibration had worn through the insulation, causing intermittent signal issues. Total fix was 95 Euro, mainly labor costs for tracking down the loose connection and replacing the wiring harness section. The turbo system itself was actually fine, which was a relief. Before jumping to conclusions though, what specific boost pressure readings are you getting? Any diagnostic codes stored? These details would help narrow things down, as similar symptoms could point to either the sensor itself, wiring, or an actual boost leak in the air intake system. Worth checking the simple stuff first, make sure all intake hoses are tight and inspect for any obvious boost leaks. The Sail's turbo setup is pretty similar to the Aveo's, so I might be able to point you to specific areas to check once you share more details.

Thanks for the feedback. My diagnostic scan showed P0236 and P0299 codes, pointing to a turbocharger boost issue. My mechanic just did a smoke test and found a tiny crack in the intercooler pipe near the turbo connection. The boost sensor readings were fluctuating between 5-12 PSI when they should be steady around 15 PSI at full load. Last service was just 2,000 km ago at 72,826, where they did a routine oil change and filter replacement. No turbo-related work was done then. Hoping it's just the pipe and not the turbocharger itself that needs replacing, given the consistent engine light and power delivery issues.

Yeah, those diagnostic codes plus the smoke test results definitely confirm what we're dealing with. On my Aveo, I initially thought it was just the pressure sensor acting up, but a proper smoke test revealed similar intercooler pipe issues. The location near the turbo connection is actually a common failure point on these engines. The fluctuating boost readings (5-12 PSI) match exactly what I experienced, it's a classic sign of boost leakage rather than a faulty sensor. The check engine light and power loss issues clear up completely once you fix the leak in the turbo system. Looking at your mileage, this is pretty typical timing for these issues to show up. My intercooler pipe cracked around 75,000 km. The good news is that replacing just the pipe is way cheaper than a full turbocharger replacement. When I had mine fixed, the turbo itself was perfectly fine, these symptoms are much more consistent with boost leaks than actual turbocharger failure. Just make sure your mechanic pressure tests the entire system after replacing the pipe. Sometimes there can be multiple small leaks that only become noticeable after fixing the main one. The complete repair should restore your boost pressure to that steady 15 PSI you mentioned.

Thanks for breaking that down. I'll have them replace the cracked intercooler pipe and do a full pressure test of the turbo boost system. Hoping this fixes both the check engine light and power issues, really don't want to deal with a bigger turbocharger problem. I'll get them to monitor the boost pressure sensor readings after the repair to make sure they stabilize at the correct PSI. Makes sense about checking for other potential leaks too, since the intake manifold and all the connections should be properly sealed for the turbo to work right. Will update once the work is done, but feeling more confident now that we've pinpointed the boost leak. Good to know the turbo itself is likely fine, since that would be a much bigger repair bill.