ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and QSL9 Engines – 010-033   Turbocharger

Initial Check

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Remove the intake pipe from the turbocharger. See the Remove section in this procedure.

If equipped with an engine mounted air cleaner, Refer to Procedure 010-013 in Section 10.

Inspect the turbocharger compressor impeller blades for damage.

Replace the turbocharger if damage is found. See the Remove and Install sections in this procedure.

If the compressor impeller is damaged, inspect the intake piping and filter element for damage.

Repair any damage before operating the engine.

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 CAUTION 

Be sure to tie the exhaust piping up above the water line to prevent water from feeding back into the vessel while the exhaust piping is removed. Failure to do so can result in the vessel sinking.

Remove the exhaust pipe from the turbocharger. See the Remove section in this procedure.

If equipped with sea water cooled exhaust outlet, Refer to Procedure 011-017 in Section 11.

Inspect the turbine wheel for damage.

Replace the turbocharger if damage is found. See the Remove and Install sections in this procedure.

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Axial Clearance Check:

Use dial depth gauge, Part Number ST-537.

Push the rotor assembly away from the gauge.

Set the gauge on zero.

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Push the rotor assembly toward the gauge and record the reading.

Axial Clearance (HX40WG – Wastegate)

mm in
0.025 MIN 0.001
0.127 MAX 0.005

Axial Clearance (HY40V – Variable Geometry)

mm in
0.025 MIN 0.001
0.127 MAX 0.005

Axial Clearance (HX55 – Wastegate, Water Cooled)

mm in
0.038 MIN 0.0015
0.093 MAX 0.0037

Replace the turbocharger if the clearance does not meet the specifications. See the Remove and Install sections in this procedure.

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Radial Clearance Check:

Use a wire-type feeler gauge to measure the clearance between the turbocharger compressor wheel and turbocharger compressor housing.

Gently push the compressor wheel toward the compressor housing and gauge.

Record the clearance.

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With the feeler gauge in the same location, gently push the turbocharger compressor wheel away from the turbocharger compressor housing and measure the clearance between the compressor wheel and housing.

Subtract the smaller clearance from the larger clearance. This is the radial bearing clearance.

Wastegate Radial Bearing Clearance (HX40WG – Wastegate)

mm in
0.330 MIN 0.013
0.508 MAX 0.020

Radial Bearing Clearance (HX55 – Wastegate, Water Cooled)

mm in
0.044 MIN 0.0172
0.608 MAX 0.0239

For variable geometry turbochargers, check the radial movement of the rotor system by pushing the turbocharger compressor wheel toward the wall of the compressor cover with light finger pressure. The turbocharger passes inspection if the wheel does not contact the compressor cover wall.

Repeat the procedure on the turbocharger turbine wheel.

Replace the turbocharger if the radial bearing clearance does not meet specifications. See the Remove and Install sections in this procedure.

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Leak Check:

Inspect the turbocharger compressor intake and discharge for oil.

If oil is present in the compressor intake, as well as in the discharge, check upstream in the turbocharger for the source of the oil.

NOTE: Some marine engines have a closed crankcase breather system which is connected to the engine mounted air cleaner assembly. Check the closed crankcase breather system. Refer to Procedure 010-013 in Section 10.

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If oil is present only in the discharge side, install the air intake and charge-air cooler piping, or the aftercooler piping. Refer to the OEM service manual. If equipped with an aftercooler, Refer to Procedure 010-005 in Section 10.

If oil is present only in the discharge side, install the air intake and charge-air cooler piping. Refer to OEM service manual.

Check for intake restriction. Refer to Procedure 010-031 in Section 10.

NOTE: If the engine experiences a turbocharger malfunction or any other occasion where oil is put into the charge-air system, the charge-air system must be inspected and cleaned. Refer to Procedure 010-027 in Section 10. If equipped with an aftercooler, Refer to Procedure 010-005 in Section 10.

NOTE: If the engine experiences a turbocharger failure that resulted in coolant, or oil entering the intake, the charge-air cooler system as well as the EGR differential pressure cross drillings should be inspected and cleaned. Use the following procedure for the charge-air cooler. Refer to Procedure 010-027 in Section 10. Use the following procedure for differential pressure cross drillings. Refer to Procedure 010-080 in Section 10.

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If the crankcase pressure is within specifications, replace the turbocharger. See the Remove and Install sections in this procedure.

NOTE: If the engine experiences a turbocharger malfunction that results in coolant or oil entering the intake, the charge-air cooler system, as well as the EGR differential pressure cross drillings, are to be inspected and cleaned. Clean and inspect the charge-air cooler system. Refer to Procedure 010-027 in Section 10. Clean and inspect the EGR differential pressure cross drillings. Refer to Procedure 010-080 in Section 10.

NOTE: If the engine experiences a turbocharger malfunction or any other occasion where oil is put into the exhaust, the aftertreatment components must be inspected. Inspect the aftertreatment diesel oxidation catalyst. Refer to Procedure 011-049 in Section 11. Inspect the aftertreatment diesel particulate filter. Refer to Procedure 011-041 in Section 11.


Add 1 unit of fluorescent tracer, Part Number 3376891, to each 38 liters [10 gal] of engine lubricating oil.

Operate the engine at low idle for 10 minutes.

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Shut off the engine.

Allow the turbocharger to cool.

Remove the exhaust pipe from the turbine housing. See the Remove section in this procedure,

if equipped with a sea water cooled exhaust outlet. Refer to Procedure 011-017 in Section 11.

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Use a high-intensity black light, Part Number 3163339, to inspect the turbine outlet for leaks.

A yellow glow indicates an oil leak. A dark blue glow indicates fuel in the oil.

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If oil is found in the turbine housing, remove the oil drain line and check for restrictions. Refer to Procedure 010-045 in Section 10.

Clear any restrictions found.

Install the turbocharger drain line. Refer to Procedure 010-045 in Section 10.

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If the oil drain line was not restricted, remove the turbocharger. See the Remove and Install sections in this procedure.

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If these checks do not reveal the problem, remove the turbocharger. See the Remove and Install sections in this procedure.

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Use a high-intensity black light, Part Number 3163339, to inspect the turbine inlet for leaks.

A yellow glow indicates an oil leak from the engine.

If a yellow glow is not seen in the turbine inlet, replace the turbocharger. See the Remove and Install sections in this procedure.

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Install the exhaust pipe to the turbocharger turbine outlet and tighten the clamp. See the Install section in this procedure, if the exhaust outlet is sea water cooled.

Refer to Procedure 011-017 in Section 11.

Install the intake pipe to the turbocharger compressor inlet and tighten the clamp. See the Install section in this procedure, if equipped with an engine mounted air cleaner.

Refer to Procedure 010-013 in Section 10.

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Locally manufacture a turbocharger coolant leak test kit to connect to the coolant inlet and outlet.

  • An air pressure regulator is required to control shop air pressure during the test.
  • A M14x1.5 male plug is required to block the water outlet.
  • A hose with an appropriate fitting to connect to the air pressure regulator and a 13/16”-16 female flat face o-ring fitting is required to connect to the water inlet.
 
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Apply shop air supply to pressurize the turbocharger coolant passage to 276 kPa [40 psi].

Close the air pressure regulator.

Check the gauge for a pressure decrease. The pressure must not decrease more than 34 kPa [5 psi] in 1 minute.

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If the pressure decrease is more than 34 kPa [5 psi] in 1 minute, use a spray bottle of soapy water to wet all hose connections. Bubbles will appear if the connections are leaking.

If the pressure decreases and the hose connections are not leaking, replace the turbocharger.

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Preparatory Steps

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Marine Applications


 WARNING 

Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.
 WARNING 

Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.
 CAUTION 

Use caution when draining oil or replacing filters that oil is not spilled or drained into the bilge area. The oil and oil filters must be discarded in accordance with local environmental regulations.
 CAUTION 

Use caution when draining coolant that coolant is not spilled or drained into the bilge area. Do not pump the coolant overboard. If the coolant is not reused, it must be discarded in accordance with local environmental regulations.
 CAUTION 

Be sure to tie the exhaust piping up above the water line to prevent water from feeding back into the vessel while the exhaust piping is removed. Failure to do so can result in the vessel sinking.

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Remove

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Marine Applications


 WARNING 

This component or assembly weights greater than 25kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift the component or assembly.
 CAUTION 

The gasket water ports are larger on the top and bottom passages. The gasket is also marked “Turbocharger” on the side facing the turbocharger. The gasket must be installed with the port size matching the ports of the exhaust manifold and turbocharger, and with the “Turbocharger” marking facing the turbocharger to prevent damage to the turbocharger from overheating.

Remove the turbocharger mounting nuts and turbocharger.

Remove the gasket.

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Clean and Inspect for Reuse

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Clean the turbocharger and exhaust manifold gasket surfaces.

Inspect the turbocharger and exhaust manifold gasket surfaces, and the mounting studs for cracks or other damage.

Replace the exhaust manifold if any cracks or other damage is found in the mounting flange surfaces. Refer to Procedure 011-007 in Section 11.

For wet manifolds, use the following procedure. Refer to Procedure 011-008 in Section 11.

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Turbocharger Flatness Check:

Place a ruler over the manifold mounting surface.

Measure with a feeler gauge the gap between the port surface and the ruler.

mm in
Mounting Surface Flatness Specification   0.1 MAX 0.004

If the mounting surface is out of specfication, the turbocharger must be replaced.

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 WARNING 

When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.
 WARNING 

When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam can cause serious personal injury.
 WARNING 

Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Remove all carbon deposits and gasket material from surfaces.

Use solvent or steam to clean the exterior of the turbocharger.

Dry with compressed air.

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Inspect the turbine and compressor housings.

If cracks that go all the way through the outer walls are found, the turbocharger must be replaced.

NOTE: A charge air cooler failure can cause progressive damage to the turbine housing. If the turbine housing is damaged, check the charge air cooler. Refer to Procedure 010-027 in Section 10.

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Install

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Marine Applications


 WARNING 

This component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this component.
 CAUTION 

The gasket water ports are larger on the top and bottom passages. The gasket is also marked “Turbocharger” on the side facing the turbocharger. The gasket must be installed with the port size matching the port size of the exhaust manifold and turbocharger, and with the “Turbocharger” marking facing the turbocharger to prevent damage to the turbocharger from overheating.

Apply a film of high-temperature anti-seize compound to the turbocharger mounting studs.

Use a new gasket and install the turbocharger.

Install and tighten the four mounting nuts.

NOTE: The torque values given have been established using anti-seize compound as a lubricant.

Torque Value:  43  n.m  [32 ft-lb]

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Prime

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Install the turbocharger oil drain line. Refer to Procedure 010-045 in Section 10.

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Lubricate the bearings by pouring 59 to 89 ml [2 to 3 oz] of clean 15W40 engine oil into the turbocharger oil supply line fitting. Rotate the turbine wheel to allow oil to enter the bearing housing.

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Finishing Steps

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Marine Applications


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Last Modified:  03-Aug-2010