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| Illustration 1 | g01015339 |
Rear view of engine Exhaust bypass actuator (wastegate) | |
(1) Hardware (nuts, bolts and washers)
(2) Axial stop plates
(3) Housing (exhaust bypass)
(4) Bypass plate and shaft
(5) Plate
(6) Lever (exhaust bypass)
(7) Adjustable rod
(8) Lever (cross shaft to adjustable rod)
(9) Bearing assemblies for cross shaft
- Diameter of cross shaft for bearings ... 15.739 ± 0.510 mm (0.6196 ± 0.0200 inch)
- Bore in bearings for cross shaft ... 15.880 ± 0.005 mm (0.6252 ± 0.0002 inch)
(10) Lever (wastegate)
Note: The end of shaft for the wastegate is stamped "W/G END".
(11) Adjustable rod (actuator to cross shaft)
(12) Actuator shaft and lever
(13) Pointer for the actuator assembly
(14) Angle of the cross shaft lever
(15) Angle of the actuator lever
Use the following procedure in order to adjust the wastegate and the actuator linkage.
- Apply 5P-3931 Anti-Seize Compound to the threads of all the hardware for the exhaust system (1) that is exposed to the full exhaust temperatures.
- Assemble the bypass plate (wastegate) and shaft (4) in housing (3). Leave the mounting bolts loose.
- Assemble axial stop plates (2), plate (5) and the cover. Tighten the cover bolts.
Torque ... 47 ± 9 N·m (35 ± 7 lb ft)
- Hold the wastegate's plate in the fully closed position. Tighten the mounting bolts.
Torque ... 12 ± 3 N·m (9 ± 2 lb ft)
- Install lever (6) on the shaft for the exhaust bypass (wastegate).
- Install the cross shaft through bearing assemblies (9). Orient the stamped end of the shaft toward the wastegate. Install lever (10) on the stamped end of the shaft.
- Provide equal thread engagement of the rod ends on adjustable rod (7). Install the rod between the wastegate and cross shaft levers. Adjust the rod length so that bypass plate (wastegate) and shaft (4) is fully closed. The angle for cross shaft lever (14) is 19.0 ± 1.5 degrees. Tighten the rod end nuts.
Torque ... 25 ± 6 N·m (18 ± 4 lb ft)
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| Illustration 2 | g01015442 |
- Hold the actuator shaft in the closed position. Install the actuator lever on the actuator shaft. The angle of actuator lever (15) is 12.5 ± 1.5 degrees counterclockwise from the vertical centerline of the actuator shaft.
- Provide equal thread engagement of the rod ends on adjustable rod (11). Install the rod between lever (8) and the actuator shaft and lever (12) .
- Hold the exhaust bypass (wastegate) in the closed position. Adjust the length of adjustable rod (11) so that the pointer for actuator assembly (13) is at the eight percent position.
Note: The actuator indicator is calibrated in order to show the percentage that the wastegate is open or the wastegate is closed. An indicator reading of eight percent is equal to approximately 7.5 degrees counterclockwise from the 0 position.
- Tighten the rod end nuts of adjustable rod (11) .
Torque ... 25 ± 6 N·m (18 ± 4 lb ft)