CM850 Electronic Control System – 019-405   Turbocharger Position Sensor

CAUTION  The position sensor pins can be bent if the engine harness connector is mated to the sensor connector at an angle. Therefore, the engine harness connector must be inserted straight into the position sensor connector to reduce the possibility of damaging the pins. Bent pins will result in poor engine performance and intermittent fault codes.

CAUTION  Do not use connector grease on the turbocharger position sensor connector. Use of connector grease can cause damage to the turbocharger control valve and low engine performance.

The turbocharger position sensor outputs a voltage signal to the ECM. The ECM converts this signal into a percentage, 0 to 100 percent, indicating variable geometry turbocharger position. A fully closed turbocharger is equivalent to 100 percent.

The turbocharger position sensor is located on the variable geometry turbocharger actuator assembly.

There are two types of position sensors. The original position sensor has the connector molded into the sensor (shown in the diagram). The new hull effect position sensor has a pigtail harness connected to the sensor.

Push down on the connector tab and detach the connector from the sensor.

Remove the capscrews that secure the sensor to the variable geometry turbocharger actuator assembly.

Remove the sensor.

Inspect the turbocharger position sensor for a damaged or missing o-ring and damaged or broken connector pins.

CAUTION  The position sensor pins can be bent if the engine harness connector is mated to the sensor connector at an angle. Therefore, the engine harness connector must be inserted straight into the position sensor connector to reduce the possibility of damaging the pins. Bent pins will result in poor engine performance and intermittent fault codes.

Rotate the internal hub of the sensor so it will align with the flat spot on the shaft.

Guide pins, Part Number 3165138, are necessary for proper alignment between the position sensor and the housing. Improper alignment will result in damage to the sensor.

Insert alignment pins into the capscrew holes in the housing.

CAUTION  Do not allow any of the solution to get inside the sensor. Damage to electrical components can occur.

Use a cotton swab to lubricate the sensor o-ring with a mild soap and water solution.

Install the position sensor over the guide pins.

Press the sensor into the bore until the o-ring is fully engaged.

The external locating tab on the sensor should align with the hole in the housing.

When the position sensor is fully seated against the housing, remove the alignment pins and install the two M4 capscrews.

CAUTION  Do not use connector grease on the turbocharger position sensor connector. Use of connector grease can cause damage to the turbocharger control valve and low engine performance.

Connect the engine harness connector to the sensor. Push the connectors together until they lock.

Inspect the wiring harness and connector for excessive tension.

If excessive tension is present, determine the source and relieve the tension on the circuit.