Component Tests and General Diagnostics
Turbocharger
Component Tests
Turbocharger Internal Oil Leak Test
NOTE: Some engine oil may be present in the turbocharger compressor inlet and in the air inlet components due to the crankcase breather system.
Check the turbocharger compressor inlet for evidence of oil. If excessive oil is present, this indicates that the failure could be in the engine or turbocharger. Refer to Engine or the following turbocharger checks. If excessive oil is found in the turbocharger compressor outlet, check the Charge Air Cooler (CAC) for oil contamination.
Check the turbocharger turbine outlet for evidence of oil. If excess oil is present in the outlet, remove the turbocharger from the engine and examine the oil supply and return passages in the turbocharger and engine block for restriction. If no restriction is found, install a new turbocharger.
Bearing Clearance Check
When bearing damage is suspected, verify using the following procedures.
Check Axial and Radial Shaft Movement - On Vehicle
1. With the vehicle in NEUTRAL, position it on a hoist. Refer to Vehicle Jacking and Lifting.
2. Remove the degas bottle module. Refer to Cooling System &/or Engine Block Heater.
3. Remove the Air Cleaner (ACL) and the ACL outlet pipe. Refer to Fuel Delivery and Air Induction.
4. Remove the auxiliary air intake from the vehicle.
5. Loosen the 2 bolts for the exhaust downpipe at the Oxidation Catalytic Converter (OC).
6. NOTICE: Do not lean on, pull on or use the turbocharger oil supply tube as a handle or damage to the turbocharger oil supply tube may occur.
NOTE: Use a back-up wrench to prevent the fittings from turning.
Remove the 2 turbocharger oil supply tube banjo bolts and sealing washers.
- Discard the sealing washers.
7. Remove the bolt and the turbocharger oil supply tube.
- Remove and discard the O-ring seal.
- Plug or cap the openings as needed.
8. NOTE: Roll the heat shield towards the cowl, then lift it up in the front and pull the shield forward to remove it.
Remove the 5 bolts and the turbocharger heat shield.
9. Remove the clamp at the turbocharger and position aside the exhaust downpipe.
- Remove and discard the turbocharger gasket.
10. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components. Always install Fuel System Caps to any open orifices or tubes.
Remove the 2 banjo bolts and the sealing washers at the fuel cooler.
- Discard the sealing washers.
11. Remove the 3 bolts for the turbocharger actuator cooler.
12. Remove the 2 bolts for the fuel cooler.
13. Remove the 2 stud bolts for the fuel cooler.
14. Remove the 2 retaining nuts for the fuel cooler.
15. Remove the 3 bolts for the fuel cooling system expansion tank. Position aside the turbocharger actuator cooler, fuel cooler and coolant expansion tank.
16. Remove the fuel cooler bracket.
17. Disconnect the turbocharger actuator electrical connector and pin-type retainer.
18. Remove the nut and position the oil level indicator and tube aside.
19. NOTE: Rear bolts shown, front bolts similar.
Remove the 4 bolts, the front fuel cooler bracket and the turbocharger crossover tube.
20. NOTE: The seals in the crossover tube are one-time-use seals and must be installed new every time the connection is disassembled.
NOTE: Large remover shown, small remover similar.
Position the crossover tube in a soft-jawed vise. Using the Air Crossover Seal Remover/Installer and Slide Hammer, remove and discard the turbocharger crossover seal from each end of the crossover tube.
21. Disconnect the crankcase ventilation drain tube.
22. NOTE: Use one of the turbocharger crossover tube mounting holes in the LH valve cover bracket to mount the Dial Indicator Gauge with Holding Fixture. Position the tip of the Dial Indicator arm into the depression in the end of the turbocharger shaft.
NOTE: The axial end play check is done by pushing on the end of the turbocharger shaft. Zero the Dial Indicator, then push from the other end or pull the shaft.
Using the Dial Indicator Gauge with Holding Fixture, check the high-pressure turbocharger axial end play. Compare the reading with the axial end play specification.
23. NOTE: Use one of the turbocharger crossover tube mounting holes in the LH valve cover bracket to mount the Dial Indicator Gauge with Holding Fixture. Position the tip of the Dial Indicator arm into the depression in the end of the turbocharger shaft.
NOTE: The radial shaft moment check is done by pushing up and down on the turbocharger shaft. Zero the Dial Indicator, then push up on the shaft and take a reading, then push down on the shaft and take a reading. Add the 2 readings together to get the total reading.
Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, check the high-pressure turbocharger radial shaft movement. Compare the total reading with the radial shaft movement specification.
24. NOTE: Use the valve cover stud to mount the Dial Indicator Gauge with Holding Fixture. Position the tip of the Dial Indicator arm into the depression in the end of the turbocharger shaft.
NOTE: The axial end play check is done by pushing on the end of the turbocharger shaft. Zero the Dial Indicator, then push from the other end or pull the shaft.
Using the Dial Indicator Gauge with Holding Fixture, check the low-pressure turbocharger axial end play. Compare the reading with the axial end play specification.
25. NOTE: Use a turbocharger bolt to mount the Dial Indicator Gauge with Holding Fixture. Position the tip of the Dial Indicator arm into the depression in the end of the turbocharger shaft.
NOTE: The radial shaft moment check is done by pushing up and down on the turbocharger shaft. Zero the Dial Indicator, then push up on the shaft and take a reading, then push down on the shaft and take a reading. Add the 2 readings together to get the total reading.
Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, check the low-pressure turbocharger radial shaft movement. Compare the total reading with the radial shaft movement specification.
26. Connect the crankcase ventilation drain tube.
27. NOTE: The seals in the crossover tube are one-time-use seals and must be installed new every time the connection is disassembled.
NOTE: Large installer shown, small installer similar.
Position the crossover tube in a soft-jawed vise. Using the Air Crossover Seal Remover/Installer and Handle, install a new seal in each end of the turbocharger crossover tube.
28. NOTE: Rear bolts shown, front bolts similar.
Position the turbocharger crossover tube and the front fuel cooler bracket. Install the 4 bolts for the turbocharger crossover tube.
- Tighten to 31 Nm (23 lb-ft).
29. Position back the oil level indicator and tube and install the nut.
- Tighten to 31 Nm (23 lb-ft).
30. Connect the turbocharger actuator electrical connector and pin-type retainer.
31. Position the fuel cooler bracket.
32. Position back the turbocharger actuator cooler, fuel cooler and coolant expansion tank. Install the 3 bolts for the fuel cooling system expansion tank.
- Tighten to 9 Nm (80 lb-in).
33. Install the 2 retaining nuts for the fuel cooler.
- Tighten to 19 Nm (168 lb-in).
34. NOTE: It may be necessary to loosen the front bolts of the turbocharger crossover in order to get correct alignment of the holes for the fuel cooler.
Install the 2 stud bolts for the fuel cooler.
- Tighten to 25 Nm (18 lb-ft).
35. Install the 2 bolts for the fuel cooler.
- Tighten to 9 Nm (80 lb-in).
36. NOTE: Turbocharger actuator cooler removed for clarity.
Position the turbocharger actuator cooler and install the 3 bolts. Tighten the bolts in the sequence shown in 2 stages.
- Stage 1: Finger-tighten the bolts.
- Stage 2: Tighten to 7 Nm (62 lb-in).
37. NOTICE: Use only banjo bolts with a green hex head. The green-headed bolts do not contain a check valve. When viewed from the inner end, the correct bolt will appear open. Failure to install the correct banjo bolt may result in damage to the fuel system.
NOTICE: Make sure that the fuel tubes are not rubbing against the turbocharger actuator cooler or damage to the fuel tubes may occur.
Install the new sealing washers and 2 banjo bolts at the fuel cooler.
- Tighten to 25 Nm (18 lb-ft).
38. NOTE: Install a new gasket on the turbocharger.
Position back the exhaust downpipe and install the clamp.
- Tighten to 15 Nm (133 lb-in).
39. Position the turbocharger heat shield and install the 5 bolts.
- Tighten to 11 Nm (97 lb-in).
40. NOTE: Install a new O-ring seal.
Position the turbocharger oil supply tube and install the bolt.
- Tighten to 13 Nm (115 lb-in).
41. NOTICE: Use only banjo bolts with a green hex head. The green-headed bolts do not contain a check valve. When viewed from the inner end, the correct bolt will appear open. Failure to install the correct banjo bolt may result in damage to the turbochargers.
NOTICE: Do not lean on, pull on or use the turbocharger oil supply tube as a handle or damage to the turbocharger oil supply tube may occur.
NOTE: Use a back-up wrench to prevent the fittings from turning.
NOTE: The back banjo bolt will require a torque adapter to be tightened properly.
Install new sealing washers and the 2 turbocharger oil supply tube banjo bolts.
- Calculate the correct torque wrench setting for the following torque.
- For Viton(R) sealing washers, using a torque adapter, tighten to 25 Nm (18 lb-ft).
- For copper sealing washer, using a torque adapter, tighten to 38 Nm (28 lb-ft).
- Verify that the turbocharger oil supply tube does not contact the turbocharger actuator linkage.
42. Tighten the 2 bolts for the exhaust downpipe at the OC.
- Tighten to 40 Nm (30 lb-ft).
43. Position the auxiliary air intake in the vehicle.
44. Install the Air Cleaner (ACL) outlet pipe and ACL. Refer to Fuel Delivery and Air Induction.
45. Install the degas bottle module. Refer to Cooling System &/or Engine Block Heater.
Check for Free Rotation - Off Vehicle
NOTE: Turbine and compressor wheels must spin freely when turned by hand. No housing contact is permitted.
Press and rotate the turbocharger shaft, then repeat from the opposite side. If either the compressor wheel or the turbine wheel contacts the housing, the bearings are bad and a new turbocharger must be installed.
Check Axial End Play - Off Vehicle
1. NOTE: Use a turbocharger bolt to mount the Dial Indicator Gauge with Holding Fixture. Position the tip of the Dial Indicator arm into the depression in the end of the turbocharger shaft.
NOTE: The axial end play check is done by pushing on the end of the turbocharger shaft. Zero the Dial Indicator, then push from the other end or pull the shaft.
Using the Dial Indicator Gauge with Holding Fixture, check the high-pressure turbocharger axial end play. Compare the reading with the axial end play specification.
2. NOTE: Use a turbocharger bolt to mount the Dial Indicator Gauge with Holding Fixture. Position the tip of the Dial Indicator arm into the depression in the end of the turbocharger shaft.
NOTE: The axial end play check is done by pushing on the end of the turbocharger shaft. Zero the Dial Indicator, then push from the other end or pull the shaft.
Using the Dial Indicator Gauge with Holding Fixture, check the low-pressure turbocharger axial end play. Compare the reading with the axial end play specification.
Check Radial Shaft Movement - Off Vehicle
1. NOTE: Use a turbocharger bolt to mount the Dial Indicator Gauge with the Holding Fixture. Position the tip of the Dial Indicator arm into the depression in the end of the turbocharger shaft.
NOTE: The radial shaft movement check is done by pushing up and down on the turbocharger shaft. Zero the Dial Indicator, then push up on the shaft and take a reading, then push down on the shaft and take a reading. Add the 2 readings together to get the total reading.
Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, check the high-pressure turbocharger radial shaft movement. Compare the total reading with the radial shaft movement specification.
2. NOTE: Use a turbocharger bolt to mount the Dial Indicator Gauge with Holding Fixture. Position the tip of the Dial Indicator arm into the depression in the end of the turbocharger shaft.
NOTE: The radial shaft movement check is done by pushing up and down on the turbocharger shaft. Zero the Dial Indicator, then push up on the shaft and take a reading, then push down on the shaft and take a reading. Add the 2 readings together to get the total reading.
Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, check the low-pressure turbocharger radial shaft movement. Compare the total reading with the radial shaft movement specification.