- Engine:
- C-16 (S/N: 7CZ1-UP)
This engine uses a wastegate solenoid in order to control the maximum boost pressure that is generated by the turbocharger. The wastegate diaphragm is preset at the factory to 146 ± 3 kPa (21.2 ± .4 psi) and the diaphragm is not adjustable.
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.
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 following items are necessary in order to check the calibration of the wastegate actuator.
- Use 215-2592 Tool Kit
- An air pressure regulator
- An air pressure gauge for 0 kPa (0 psi) to 207 kPa (30 psi) with 1.7237 kPa (0.25 psi) graduations
- A tee or a cross
- A hose barb coupler
- An air valve
- An air supply
- A fitting for connection to the air supply
- A dial indicator with base that can be attached to the engine
- A test hose 161-6960 Hose with a 6.35 mm (0.25 inch) inner diameter for connection to the wastegate actuator
- Two 161-6963 Clamps (Hose)
Note: A 213-4269 Crimping Tool will also be required at final installation.
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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 215-2592 Hose with a 6.35 mm (0.25 inch) inner diameter for connection to the wastegate actuator (J) 161-6963 Clamps (Hose) | |
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 |
- Set the air pressure regulator (A) to 0 kPa (0 psi).
- 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 7. Observe the pressure gauge (B) and record the pressure reading.
- This pressure reading is the calibration reading of the actuator.
The Actuation Calibration Reading is Between141 kPa (20.5 psi) and 151 kPa (21.9 psi)
No further action is necessary if the actuator calibration reading is above 141 kPa (20.5 psi) and below 151 kPa (21.9 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 141 kPa (20.5 psi) or Above 151 kPa (21.9 psi)
The turbine housing must be replaced if the actuation calibration reading is below 141 kPa (20.5 psi)and/or above 151 kPa (21.9 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".