Note: Before you begin this test, ensure that you do not have any diagnostic codes that are stored in the ECM. Refer to the Troubleshooting Guide for more information.
The calibration of the wastegate actuator should be checked when a low boost condition is suspected. After the calibration has been checked, the proper course of resolution may be determined.
The following items are necessary in order to check the calibration of the wastegate actuator.
- 215-2592 Tool Kit
- An air supply
- A fitting for connection to the air supply
- A dial indicator with base that can be attached to the engine
- Use 161-6960 Hose
- Two 161-6963 Clamps (Hose)
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| Illustration 1 | g00867065 |
Tools that are required in order to measure the air pressure during the calibration of the wastegate actuator (A) Air pressure regulator (B) Air pressure gauge (C) Tee or cross (D) Hose barb coupler (E) Valve for use with cross (F) Valve (G) Fitting for connection to the air supply (H) Test hose 161-6960 (J) 161-6963 Clamps (Hose) | |
The following part will be required in order to replace the wastegate actuator, if necessary.
- A 225-0319 Actuator Kit
A crimping tool 213-4269 will also be required at final installation.
- Inspect the lines for the wastegate solenoid for any signs of damage. Repair the damage as it is necessary.
- Disconnect the hose from the wastegate diaphragm.
- Apply 138.1 kPa (20.03 psi) of air to the wastegate diaphragm.
- Observe the movement of the dial indicator needle. The measurement of the movement of the actuator rod should be 1.0 mm (0.039 inch).
Note: Inspect the wastegate for damage if the wastegate is not within specifications. Replace the wastegate if the movement of the actuator rod is not within specifications.
Determine the Actuation Calibration Reading
- Allow the turbocharger to cool.
- Install dial indicator (1) on the engine. The travel of the dial indicator must align with the travel of the rod (2) or an error in the measurement will occur. Refer to Illustration 2.
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| Illustration 2 | g00918362 |
- Remove the hose (4) from the actuator (3) .
- Connect the air supply to the air pressure regulator (A) .
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| Illustration 3 | g00918469 |
- Connect the test hose (H) to the actuator (3) with hose clamps (J) .
- Turn the knob on air pressure regulator (A) and slowly increase the air pressure while you observe the dial indicator (1). Increase the air pressure until the travel of the rod (2) is 1.00 mm (0.039 inch). Observe the pressure gauge (B) and record the pressure reading.
- Turn the knob on air regulator (A) and slowly decrease the pressure to 0 kPa (0 psi). Repeat Step 6. Observe the pressure gauge (B) and record the pressure reading.
- This pressure reading is the Actuator Calibration Reading.
The Actuation Calibration Reading is Above 128 kPa (18.5 psi)
No further action is necessary if the actuator calibration reading is above 128 kPa (18.5 psi). Remove the test hose and all test equipment. Install the hose for the actuator. Be sure that the hose is not kinked. Be sure that the hose does not rub at any point. Continue with an alternate diagnosis.
The Actuation Calibration Reading is Below 103 kPa (15 psi)
The turbine housing must be replaced if the actuation calibration reading is below 103 kPa (15 psi). Remove the test hose and all test equipment and replace the turbine housing. Refer to Disassembly and Assembly, "Turbocharger - Disassemble" and Disassembly and Assembly, "Turbocharger - Assemble".
The Actuation Calibration Reading is Between 103 kPa (15 psi) and 128 kPa (18.5 psi)
The actuator must be replaced and recalibrated if the actuation calibration reading is between 128 kPa (18.5 psi) and 103 kPa (15 psi). Replace the wastegate actuator with a 225-0319 Actuator Kit. Refer to "Installation and Calibration of a New Wastegate Actuator".
Installation and Calibration of a New Wastegate Actuator
Use the following procedures in order to install a 225-0319 Actuator Kit and calibrate the new wastegate actuator.
- Apply 138 kPa (20 psi) of air pressure to the actuator (3). Remove the clip (5) from the crank pin. Discard the clip (5) .
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| Illustration 4 | g00918562 |
- Reduce the air pressure to 0 kPa (0 psi) and remove the test hose (H) from the actuator (3) .
- Note the orientation of the hose nipple (6) on the actuator (3). Remove the nuts (7) that fasten the actuator to the bracket and remove the actuator. Do not remove the bracket.
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| Illustration 5 | g00918611 |
- Refer to Illustration 6 and Illustration 7. Assemble the new actuator (8), jam nut (10), and rod end (11) that is included in the 225-0319 Actuator Kit .
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| Illustration 6 | g00918624 |
(8) New actuator (9) Nut (10) Jam nut (11) Rod end (12) Clip | |
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| Illustration 7 | g00918625 |
(X) Same length as the old actuator | |
- Be sure that the hose nipple (6) is oriented in the same position as the original actuator. Install the new actuator (8) on the turbocharger. Fasten the new actuator to the bracket with the nuts (9) that are included in the 225-0319 Actuator Kit .
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| Illustration 8 | g00918656 |
- Connect the test hose (H) to the new actuator (8). Apply 138.1 kPa (20.03 psi) of air pressure to the new actuator. Place the rod end of the new actuator over the crank pin. Reduce the air pressure to 0 kPa (0 psi).
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| Illustration 9 | g00918664 |
- Determine the actuation calibration reading. Refer to "Determine the Actuation Calibration Reading" in this article.
- Install the new clip (12) from the 225-0319 Actuator Kit on the crank pin if the actuator calibration reading from Step 7 is 138.1 ± 3 kPa (20.03 ± 0.5 psi). Tighten the jam nut (10) against the rod end (11) of the actuator. Crimp the rod end (11) to the actuator rod. If the actuator calibration reading from Step 7 is above 141 kPa (20.5 psi), refer to "The Actuation Calibration Reading for the New Wastegate Actuator is Above 141 kPa (20.5 psi)". If the actuator calibration reading from Step 7 is below 134.5 kPa (19.50 psi) refer to "The Actuation Calibration Reading for the New Wastegate Actuator is Below 134.5 kPa (19.50 psi)".
- Remove the test hose and all test equipment. Install the hose (4) on the actuator. Make sure that hose (4) is not kinked. Make sure that the hose does not rub at any point.
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| Illustration 10 | g00918671 |
- Record the original actuator calibration reading and record the new actuator calibration reading in the appropriate entry of the Service Information Management System (SIMS).
The Actuation Calibration Reading for the New Wastegate Actuator is Above 141 kPa (20.5 psi)
Use the following procedure if the actuator calibration reading is above 141 kPa (20.5 psi).
- Remove the rod end from the crank pin. Turn the rod end in a counterclockwise direction. The actuator calibration reading will decrease approximately 4 kPa (0.6 psi) for every one half turn of the rod end.
- Determine the actuation calibration reading. Refer to "Determine the Actuation Calibration Reading" in this article.
- If the actuator calibration reading is above 141 kPa (20.5 psi) repeat Step 1 and Step 2.
- Install the new clip from the 225-0319 Actuator Kit on the crank pin if the actuator calibration reading from Step 2 is 138 ± 3.5 kPa (20 ± 0.50 psi). Tighten the jam nut against the rod end of the actuator. Crimp the rod end to the actuator rod.
- Remove the test hose and all test equipment. Install hose (4) on the actuator. Make sure that the hose is not kinked. Make sure that the hose does not rub at any point.
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| Illustration 11 | g00918671 |
- Record the original actuator calibration reading and record the new actuator calibration reading in the appropriate entry of the Service Information Management System (SIMS).
The Actuation Calibration Reading for the New Wastegate Actuator is Below 134 kPa (19.5 psi)
Use the following procedure if the actuator calibration reading is below 134 kPa (19.5 psi).
- Remove the rod end from the crank pin. Turn the rod end in a clockwise direction. The actuator calibration reading will increase approximately 4 kPa (0.6 psi) for every one half turn of the rod end.
- Determine the actuation calibration reading. Refer to "Determine the Actuation Calibration Reading" in this article.
- If the actuator calibration reading is below 134 kPa (19.5 psi) repeat Step 1 and Step 2.
- Install the new clip from the 225-0319 Actuator Kit on the crank pin if the actuator calibration reading from Step 2 is 138 ± 3.5 kPa (20 ± 0.50 psi). Tighten the jam nut against the rod end of the actuator. Crimp the rod end on the actuator rod.
- Remove the test hose and all test equipment. Install hose (4) on the actuator. Make sure that the hose is not kinked. Make sure that the hose does not rub at any point.
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| Illustration 12 | g00918671 |
- Record the original actuator calibration reading and record the new actuator calibration reading in the appropriate entry of the Service Information Management System (SIMS).