Use a clean cloth to wipe around the surface where the turbocharger actuator seals to the turbocharger.
NOTE: Take care not to drop any dirt or debris into the turbocharger.
Inspect the sealing surface for signs of leaks, cracks, or other damage.
If the sealing surface of the turbocharger is causi ng a leak, it is necessary to replace the entire turbocharger. Do not
continue with this procedure. Refer to Procedure 010-033 in Section 10.
If the sealing surface of the actuator is causing a leak, replace only the actuator.
Inspect the cup plugs on the actuator mating surface for signs of corrosion.
If there is corrosion in the cup plugs, pressurize the turbocharger coolant passages to test for leaking cup plugs.
Install and tighten a STORM plug into the coolant drain port on the turbocharger bearing housing.
Torque Value: 11 Nโขm [ 97 in-lb ]
Install and tighten a Compuchek’u or other appropriate air fitting into the coolant supply port.
Torque Value: 11 Nโขm [ 97 in-lb ]
Apply regulated shop air with pressure at 4 Bar [59 psi] .
Use a solution of soapy water to inspect cup plugs for leaks.
Confirm the actuator is disconnected from the engine harness. Rotate the output pinion gear by hand. Do not
use any tools to turn the gear.
Inspect the pinion gear on the actuator for seizure, excessive wear, or damaged teeth.
Replace the actuator if the pinion gear is seized, or if the teeth are worn or damaged.
Inspect the sector gear on the turbocharger for excessive wear, damaged teeth, or a broken shaft.
There are solid end stops in the turbocharger which limit sector gear travel in the clockwise and counterclockwise directions.
Use a sector gear travel gauge, Part Number 4919281, to be sure the sector gear moves through its operational range.
NOTE: It may take considerable force to move the sector gear. If it can be moved by hand, this is considered acceptable.
The sector gear travel gauges are designed for specific turbocharger models. To determine the correct gauge, verify the turbocharger model number from the turbocharger data plate. Select the gauge that matches the first three characters of the model numbers, such as He5xx or He4xx.
NOTE: The He3xx gauge is unique and will only fit the He3xx turbocharger.
To install the sector gear travel gauge, carefully bend the gauge and slide the thin section under the sector gear. If
necessary, pull the sector gear out by hand to allow more clearance for the gauge. Verify that the three alignment
bosses are fully engaged in the bearing housing.
Rotate the sector gear counterclockwise towards the turbocharger compressor cover. The edge of the sector
gear must be in the green acceptance zone of the gauge.
Rotate the sector gear clockwise toward the turbocharger turbine housing. The edge of the sector gear must be in
the green acceptance zone of the gauge.
If the sector gear does not go through its entire range of motion, or if the sector gear is seized, it is necessary to
replace the entire turbocharger assembly. Do not continue with this procedure. Refer to Procedure 010-033
in Section 10.
