Method D, Turbo Only, All Markets Except US/CDN

REPLACING THE WASTE-GATE ACTUATOR ONLY

NOTE: Method "A" should be performed prior to this method if the vehicle is older than M/Y 96 (production date 03/96).





Parts Required:
- Waste-gate actuator kit 1270463-1





Replacing Waste-gate Actuator
D1 Disconnect:
- Fresh air hose from Turbo-Charger (TC) and push aside.





D2 Remove:
- Clamp supporting charge air pipe by engine torque control arm.





D3 Remove:
- Lower clamp by Turbo-Charger (TC).
Fold charge air pipe out of the way.

NOTE: Cover Turbo-Charger (TC) outlet with paper to stop debris getting into it.





D4 Remove:
- Heat deflector plates
- Ground strip.





D5 Remove:
- Lock pin at waste-gate
- Waste-gate actuator screw (1)
- Waste-gate actuator screw (2).

Install:
- New waste-gate actuator
- Screws and tighten to 20 Nm.





D6 Carry out basic adjustment of pressure arm:
- Connect manometer 999 5230 and pressure tester 998 5496 to pressure servo
- Pump up pressure to 12.5 kPa (1.82 psi)
- Pump waste-gate actuator spindle towards turbine housing (closed valve)
- Adjust pressure arm so that it fits onto spindle lug exactly
- Install lock pin at waste-gate
- Tighten pressure arm locknut
- Remove manometer and pressure tester.

NOTE: The tester arm must not be twisted when adjusting it. Otherwise the pressure servo membrane may be damaged.





Installing Parts
D7 Install:
- Heat deflector plates.
- Ground strip.





D8 Remove:
- Cover from Turbo-Charger (TC) outlet.

Install:
- The charge air pipe.





D9 Install:
- Clamp supporting charge air pipe by engine torque control arm.





D10 Install:
- Fresh air hose to Turbo-Charger (TC).

D11 Perform test drive:
- Check that there are no DTC's stored in the system after the test drive.