NOTE: Following these instructions in order is very important.
• Continue through the entire turbocharger actuator installation procedure before attempting to troubleshoot any other fault codes.
• Verify that the turbocharger actuator is removed from the turbocharger bearing housing.
• Verify that the turbocharger actuator electrical connector is disconnected from the engine wiring harness.
• Turn the keyswitch ON. Connect INSITE’M electronic service tool and wait 60 seconds.
• Connect the turbocharger actuator electrical connector to the engine wiring harness.
If Fault Code 2634 becomes active, disconnect the turbocharger actuator connector from the engine wiring
harness with the keyswitch ON. Connect the turbocharger actuator electrical connector. Fault Code 2634 will go
inactive.
It is normal and expected to have Fault Code 2449 active when a new turbocharger actuator is connected to the
engine , because it is not calibrated to the turbocharger.
Continue through the engine turbocharger actuator installation procedure before attempting to troubleshoot any other fault codes.
In INSITE’.. electronic service tool, go to the ECM Diagnostic Tests screen.
From the list, select VGT Electronic Actuator Installation and Calibration, and click on the “next” button.
NOTE: The VGT Electronic Actuator Installation and Calibration is not a diagnostic test. It is the procedure
used to properly install and calibrate the turbocharger actuator. Running this procedure improperly can result in
additional fault codes and/or damage to the turbocharger or actuator.
The INSITE electronic service tool INSTALL ACTUATOR command must only be run with the actuator not
mounted to the turbocharger.
Locate the column labeled Value and left click on the down arrow. Select INSTALL ACTUATOR and select START.
This will set the actuator pinion gear to a known position to prepare it for installation to the turbocharger. This step
should take less than 30 seconds to complete with INSITE electronic service tool.
INSITE electronic service tool will indicate when this step is complete.
Do not move the actuator gear after this point.
Fault Code 2449 will be active at this point in the procedure. Continue through the turbocharger actuator
procedure before troubleshooting any fault codes.
If at any point, INSITE electronic service tool status message indicates the procedure was stopped or failed,
leave the key ON and cycle the power to the actuator by disconnecting it from the harness and connect it again.
If cycling power to the actuator does not work, unplug the actuator, turn the keyswitch OFF for 30 seconds, and start
INSITE electronic service tool. Then start over, beginning with the actuator INSTALL step.
With the sector gear travel gauge installed, grasp the sector gear by hand and rotate the sector gear toward the
turbocharger turbine housing. Be sure the edge of the sector gear is rotated all the way toward the Install Position arrow.
Coat the teeth on the sector gear with the grease packet supplied in the installation kit.
For turbochargers with the sector gear travel limits machined into the bearing housing:
Grasp the sector gear by hand and rotate the sector gear toward the turbocharger compressor cover. Be sure the
edge of the sector gear is rotated all the way to the marking on the bearing housing. Be sure the alignment holes in the sector gear and bearing housing are aligned.
Coat the teeth on the sector gear with the grease packet supplied in the installation kit.
NOTE: It is critical for smooth reliable operation of the actuator to use the full amount of the Holset® supplied
grease.
Remove the sector gear travel gauge. Do not move the sector gear after this point.
Install two new sealing a-rings on the turbocharger actuator. Be sure to use the new capscrews available in
the turbocharger actuator mounting kit.
Insert the threaded guide pins into the diagonally opposite fastener holes in the bearing housing and locate the
actuator onto the guide pins. Slide the actuator into position, making sure the gear spigot and shroud locate
into the mating holes in the bearing housing face. Insert the long and short actuator socket head capscrews in the
remaining fastener holes and hand-tighten.
The actuator pinion gear and the turbocharger sector gear must engage smoothly. If they do not engauge smoothly,
verify that the sector gear through-hole and the bearing housing blind hole are aligned.
With the actuator aligned on the bearing housing, replace the guide pins with the actuator capscrews. Install the
remaining two capscrews.
Tighten the four capscrews in a criss-cross pattern, in two steps.
