ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and QSL9 Engines – 010-050   Turbocharger Wastegate Actuator

CAUTION  All wastegates come precalibrated and can not be adjusted in the field. Attempts to adjust the wastegate can result in engine damage.

The integral wastegate line takes boost from the turbocharger compressor outlet to the wastegate capsule.

Inspect the integral wastegate actuator hose for cracks or holes. Replace the hose if damaged.

Inspect the wastegate mounting bracket, actuator rod, and lever for damage. A bent wastegate mounting bracket, actuator rod, or lever can cause improper operation.

If the wastegate mounting bracket, actuator rod, or lever is bent, it must be replaced.

In some applications the turbocharger must be removed to test the wastegate actuator. Refer to Procedure .

Disconnect the integral boost line from the wastegate capsule.

Attach a dial indicator (1) as shown, so that its shaft is in line with the wastegate actuator rod. Set the indicator to zero.

Connect clean, regulated air pressure and a pressure gauge to the capsule. Apply 200 kPa [29 psi] to make sure the wastegate is functioning properly.

The rod must move approximately 5 mm [0.200 in] without any sticking or air leakage.

Air must not be heard, such as air leaking through a functional wastegate capsule.

A small amount of travel when air pressure is first applied is normal. The tolerance is being removed from the system.

If no movement of the actuator rod is detected, detach the actuator control rod from the wastegate lever pin.

Actuate the lever by hand to be sure that the shaft rotates freely and is not seized.

If the wastegate lever can not be moved by hand, replace the turbocharger. Refer to Procedure .

If the wastegate lever moves freely by hand, replace the turbocharger wastegate actuator.

In some applications the turbocharger must be removed in order to remove the wastegate actuator. Refer to Procedure .

Prior to removal, note position length of the control rod from the boost capsule housing and orientation of the boost capsule hose connector in relation to the mounting bracket.

Remove the retaining clip from the control lever.

Remove the integral boost line from the wastegate capsule.

CAUTION  Be careful not to bend the control lever. Engine damage can result.

Remove the boost capsule actuator rod end from the turbocharger wastegate lever. This can be accomplished by slowly applying regulated air pressure to the boost capsule until the control rod is activated.

Remove the control rod from the turbocharger wastegate lever pin.

If the boost capsule diaphragm material is ruptured and will not hold air pressure, manually pull the control rod outward in order to overcome boost capsule spring tension for removal of the control rod from the turbocharger wastegate lever pin.

Loosen the boost capsule mounting capscrews, disconnect the air supply hose, and remove the assembly from the mounting bracket.

Inspect the wastegate actuator hose for cracks or holes. Replace the hose if damaged.

Inspect the wastegate mounting bracket, actuator rod, and lever for damage. A bent wastegate mounting bracket, actuator rod, or lever can cause improper operation.

If the wastegate mounting bracket, actuator rod, or lever is bent, it must be replaced.

Fit the actuator mounting studs into the holes in the bracket, and fit both actuator mounting capscrews.

Refit the end-link onto the crank-pin. Install the control rod retaining clip.

Cut the tie wrap and remove the tie wrap and spacer piece.

Refit the air supply hose to the actuator, use the new hose clamp provided.