Pinpoint tests (turbocharger)

A1: INSPECTING TURBOCHARGER ROTOR BLADES FOR DAMAGE

1Disconnect the air cleaner outlet pipe from the turbocharger.

2Inspect the turbocharger rotor blades for damage.

• Is there visible damage to the rotor blades?

→ Yes

Go to A2.

→ No

Go to A3.

A2: CHECKING AIR INTAKE SYSTEM ELEMENTS FOR FOREIGN MATERIAL

1Check the air intake system components for signs of foreign material.

• Are there any signs of foreign material?

→ Yes

CLEAN the air intake system components. INSTALL a new turbocharger. For more information, refer to Turbocharger - 75hp or 90hp Diesel Vehicles / Turbocharger - 115hp Diesel Vehicles in this section. CHECK that the system is operating correctly.

→ No

Go to A4.

A3: CHECKING TURBOCHARGER BEARINGS FOR EXCESSIVE CLEARANCE

NOTE:A little play in the bearings is normal.

1Make sure the turbocharger rotor rotates freely in the housing.

- 1. With the turbocharger stationary, gently lift the shaft (the shaft will naturally rest in the lower bearing sections).

- 2. Make sure that the turbocharger rotor rotates freely in the housing.

• Does the rotor rotate freely in the housing?

→ Yes

GO to Fuel Delivery and Controls for further blue smoke diagnostics. For additional information, refer to Section 303-04A / 303-04B / 303-04C / 303-04D / 303-04E / 303-04F / 303-04G.

→ No

INSTALL a new turbocharger. For more information, refer to Turbocharger - 75hp or 90hp Diesel Vehicles / Turbocharger - 115hp Diesel Vehicles in this section. CHECK that the system is operating correctly.

A4: CHECKING THE TURBOCHARGER OIL FEED LINE FOR BLOCKAGE

1Disconnect the oil feed line from the turbocharger (for clarity, the catalytic converter and oil return line are shown removed).

2Connect a small piece of known good hose to the oil feed line and carefully blow out the hose.

• Are there any signs of blockage?

→ Yes

INSTALL a new turbocharger oil feed line. INSTALL a new turbocharger. For additional information, refer to Turbocharger - 75hp or 90hp Diesel Vehicles / Turbocharger - 115hp Diesel Vehicles in this section. CHECK that the system is operating correctly.

→ No

INSTALL a new turbocharger. For more information, refer to Turbocharger - 75hp or 90hp Diesel Vehicles / Turbocharger - 115hp Diesel Vehicles in this section. CHECK that the system is operating correctly.

B1: CHECKING THE TURBOCHARGER OIL RETURN LINE

1Disconnect the turbocharger oil return line from the turbocharger (catalytic converter not shown).

2Remove the turbocharger oil return line.

3Check the turbocharger oil return line for blockage or signs of damage.

• Is the turbocharger oil return line OK?

→ Yes

GO to Fuel Delivery and Controls for further blue smoke diagnostics. For additional information, refer to Section 303-04A / 303-04B / 303-04C / 303-04D / 303-04E / 303-04F / 303-04G.

→ No

INSTALL a new turbocharger oil return line. CHECK the system for proper operation.

C1: CHECK THE TURBINE BYPASS VALVE ACTUATOR CONTROL PIPE FOR BLOCKAGE

1Remove the turbine bypass valve actuator control line.

2Using a hand vacuum/pressure pump, connect one end to the turbine bypass actuator control line, operate the hand vacuum/pressure pump and observe the readings.

• Is there an indication?

→ Yes

INSTALL new turbine bypass valve actuator control line. CHECK for proper system operation.

→ No

Go to C2.

C2: CHECK FOR TURBINE BYPASS VALVE ACTUATOR DIAPHRAGM LEAKS.

1Connect one end of the turbine bypass valve actuator control line to the turbine bypass valve actuator.

2Connect the other end of the turbine bypass valve actuator control line to a hand vacuum/pressure pump.

3Operate the hand vacuum/pressure pump and observe the reading.

• Does the pump hold vacuum?

→ Yes

Go to C3.

→ No

INSTALL a new turbocharger. For more information, refer to Turbocharger - Diesel 75hp or 90hp vehicles in this section. CHECK that the system is operating correctly.

C3: CHECKING THE BOOST PRESSURE

NOTE:Boost pressure is set at the factory and is not adjustable.

1Using a boost pressure gauge and a T-connector, connect the gauge between the turbine bypass valve actuator and the turbocharger.

2Start the engine and let it run until normal operating temperature is reached.

3Increase the engine speed to 3000 rpm and monitor the readings.

• Boost pressure less than 0.5 bar?

→ Yes

CHECK the fuel system. For additional information, refer to Section 303-04A / 303-04B / 303-04C / 303-04D / 303-04E / 303-04F / 303-04G.

→ No

INSTALL a new turbocharger. For more information, refer to Turbocharger - Diesel 75hp or 90hp vehicles in this section. CHECK that the system is operating correctly.

D1: CHECKING THE VACUUM LINE OF THE VACUUM DIAPHRAGM UNIT FOR BLOCKAGE

1Disconnect the vacuum line from the vacuum diaphragm block.

2Install the special tool and connect the vacuum line of the vacuum diaphragm block.

3Operate the hand vacuum pump and observe the readings.

• Is there an indication?

→ Yes

Go to D2.

→ No

INSTALL a new vacuum line to the vacuum diaphragm unit. CHECK the system for proper operation.

D2: CHECKING THE VACUUM DIAPHRAGM UNIT FOR LEAKS

1Install the special tool on the vacuum diaphragm block.

2Operate the hand vacuum pump and observe the readings.

• Does the pump hold vacuum?

→ Yes

Go to D3.

→ No

INSTALL a new turbocharger. For more information, refer to Turbocharger - 115hp Diesel Vehicles in this section. CHECK that the system is operating correctly.

D3: CHECKING THE MOVEMENT OF THE VACUUM DIAPHRAGM BLOCK DRIVE ROD

1Install the special tool on the diaphragm blade position adjustment unit.

2Operate the hand vacuum pump until a vacuum of 65 kPa is achieved. Measure the distance traveled by the drive rod of the vacuum diaphragm block.

• Does the vacuum diaphragm block actuator rod move within 9 - 11 mm?

→ Yes

CONTACT WDS.

→ No

CHECK for signs of damage or signs of foreign material on the turbocharger blades. CHECK for proper system operation.