NOTE: Prior to removal, note position length of the control rod from the boost capsule housing and orientation of the boost capsule hose connector in relation to the mounting bracket. Disconnect the boost capsule actuator rod end from the turbocharger wastegate lever. This can be accomplished by applying regulated air pressure to the boost capsule… Read More »
Attach a dial indicator (1) as shown, so that its shaft is in line with the wastegate actuator rod. Set the indicator to zero, with no air pressure applied to the wastegate cap sule. Connect clean regulated air pressure and a pressure gauge to the capsule (2). Apply 200 kPa [29 psi] to makesure the… Read More »
Visually inspect the wastegate actuator hose for cracks or holes. Replace the hose if damaged. Visually inspect the wastegate mounting bracket, actuator rod, and lever for damage. A bent wastegate mounting bracket, actuator rod, or lever can cause improper operation. If the wastegate mounting bracket, actuator rod, or lever is bent, it must be replaced.… Read More »
Inspect the lever pin. Replace the turbine housing assembly if worn excessively. Inspect the valve and valve seat for cracks or erosion. Replace the turbine housing assembly if worn excessively. Actuate the lever by hand to be sure that the shaft rotates freely and is not seized. Check for excessive movement between the shaft and… Read More »
Measure the shaft end play. Service tool Part No. ST-537. Measure radial clearance of the shaft. The turbocharger must be removed for replacement or rebuild if the clearances are beyond these limits. Refer to the Turbocharger Shop Manual, Bulletin No. 3810321, for rebuild procedures.
It is normal for the turbocharger to emit a “whine” sound that varies in intensity depending on engine speed and load. The sound is caused by the very high rotational speed of the rotor assembly. Consequently, the sound will be more audible at full speed. If possible, operate the engine at full speed to verify… Read More »
Engine lubricating oil is used to lubricate the bearings and provide some cooling for the turbocharger. The lubricating oil supplied to the turbocharger through the supply line is at engine operating pressure. A return line connected to the bottom of the turbocharger routes the lubricating oil back to the engine lubricating oil pan. Seal rings… Read More »
Failure of the interna! components of the turbocharger can reduce its effectiveness and also cause excessive smoke and low power. A bearing failure can produce friction which will slow the speed of the rotor assembly. Failed bearings can also allow the blades of the rotor assembly to rub the housings, thus reducing the rotor assembly… Read More »
Measure the boost pressure at the intake manifold by using one of the tapped or plugged intake access holes shown in the illustration. Refer to the specifications in this section. NOTE: If the engine has charge air cooling, testing must be done to ensure that the charge air cooler system is not leaking or restricting… Read More »
Inspect for exhaust leaks at the exhaust manifold and turbocharger, gasket leaks, or exhaust pipe, muffler or catalyst restrictions. Leaks or restrictions will cause the turbine and impeller to operate at a lower speed and reduce the amount of air being forced into the cylinders. Again, the symptom will be excess smoke, low manifold pressure… Read More »