ISM, ISMe, and QSM11 – 010-113   Turbocharger, Variable Geometry Actuator

WARNING  Keep fingers and hands away from actuator link to reduce the possibility of personal injury as a result of sudden movement when air is supplied.

If using INSITE™ electronic service tool to override the turbocharger actuator position, connect the vehicle air supply line to the turbocharger actuator.

If INSITE™ electronic service tool is not being used to remove the actuator, apply 620 kPa [90 psi] to 827 kPa [120 psi] of regulated air pressure to the turbocharger actuator.

The turbocharger actuator end link to cross-shaft is a tight clearance fit. Use care to reduce the possibility of damaging the turbocharger actuator or the turbocharger or the turbocharger cross-shaft when removing the actuator.

Install the turbocharger actuator onto the turbocharger.

If not installing new turbocharger actuator, apply Threadlocker, Part Number 3824040, onto the two capscrews holding the turbocharger actuator, before installing the capscrews onto the turbocharger bearing housing.

CAUTION  The zinc anode is a sacrificial washer that reduces the possibility of corrosion of the turbocharger cross-shaft and bushing. The failure to install will result in excessive corrosion and wear to the cross-shaft bushing.

Install the snap ring onto the turbocharger cross-shaft.

Apply Threadlocker, Part Number 3824040, onto the capscrew holding the zinc anode washer before installing the zinc anode washer and the capscrew.

Turn off the override in INSITE™ electronic service tool or remove the regulated air supply.

If not already installed, install the air line to the turbocharger actuator.

Start and operate the engine.

Verify proper operation and check for air leaks.

Actuator pre-installation instructions

CAUTION  During the turbocharger actuator install test, the pinion gear on the actuator will move. Keep hands and tools away from the pinion gear during the test.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

Connect the batteries. Refer to Procedure 013-009

Do not install the turbocharger actuator on to the turbocharger bearing housing at this time.

Connect the variable geometry turbocharger actuator to the engine wiring harness.

Connect INSITE™ electronic service tool.

In INSITE™ electronic service tool, go to the screen labeled ECM Diagnostic Tests.

From the list of tests, select VGT Electronic Actuator Installation and Calibration and select Install Actuator from the drop down menu on the main screen.

This will set the actuator pinion gear to a set position to prepare it for installation to the turbocharger.

Turbocharger pre-installation instructions – grasp the sector gear by hand and rotate the sector gear toward the turbocharger compressor cover until the 5 mm [0.2 in] through hole lines up with the 5 mm [0.2 in] blind hole in the bearing housing. Use the alignment pin included in the service kit to make sure the sector gear is in the correct position prior to actuator installation.

Coat the teeth on the sector gear with the grease packet supplied in the installation kit.

NOTE: It is critical for smooth reliable operation of the actuator to use the full amount of the Cummins Turbo Technologies supplied grease.

Remove the alignment pin.

CAUTION  Do not attempt to force the actuator on to the bearing housing by using the capscrews. Misalignment and damage to the actuator or turbocharger can result.

Align the actuator and gasket assembly with the turbocharger bearing housing face using the two lower screws in the bearing housing threads.

Align the actuator to the bearing housing and slide the actuator into place by hand. The actuator pinion gear and the turbocharger sector gear must engage smoothly. If not engaged smoothly, verify that the sector gear through hole and the bearing housing blind hole are aligned and try again.

When the actuator is aligned on the bearing housing, install the remaining two capscrews.

Tighten all four capscrew in a crisscross pattern in two steps.

Connect the wiring harness.