Pinpoint tests (turbocharger)

A1: INSPECTION OF TURBO ROTOR BLADES FOR DAMAGE

1 Disconnect the air filter outlet pipe from the turbocharger.

2 Inspect the turbocharger rotor blades for damage.

• Is there visible damage to the rotor blades?

→ Yes

Go to A2.

→ No

Go to A3.

A2: CHECKING THE AIR INTAKE SYSTEM FOR FOREIGN MATERIAL

1 Check 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 - 75 HP Diesel Vehicles. or 90 hp / Turbocharger - Vehicles with 115 hp diesel engine available in this section. CHECK the system is working properly.

→ No

Go to A4.

A3: CHECK TURBO BEARINGS FOR INCREASED PLAY

NOTE: A little play in the bearings is normal.

1 Check that the turbocharger rotor rotates freely in the housing.

- 1. With the turbocharger stationary, gently lift the shaft (the shaft will naturally lie in the lower sections of the bearings).

- 2. Check that the turbocharger rotor rotates freely in the housing.

• Does the rotor rotate freely in the housing?

→ Yes

GO to ch. "Fuel supply and controls", which describes further diagnosis of blue smoke. See Section 303-04A / 303-04B / 303-04C / 303-04D / 303-04E / 303-04F / 303-04G for more information.

→ No

INSTALL a new turbocharger. For more information, refer to Turbocharger - 75 HP Diesel Vehicles. or 90 hp / Turbocharger - Vehicles with 115 hp diesel engine available in this section. CHECK the system is working properly.

A4: CHECKING TURBOCOMPRESSOR OIL SUPPLY LINE FOR CLOCKAGE

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

2 Connect a small piece of known good hose to the oil supply 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 more information, refer to Turbocharger - 75 HP Diesel Vehicles. or 90 hp / Turbocharger - Vehicles with 115 hp diesel engine available in this section. CHECK the system is working properly.

→ No

INSTALL a new turbocharger. For more information, refer to Turbocharger - 75 HP Diesel Vehicles. or 90 hp / Turbocharger - Vehicles with 115 hp diesel engine available in this section. CHECK the system is working properly.

B1: TURBO OIL RETURN LINE INSPECTION

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

2 Remove the turbocharger oil return line.

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

• Is the turbocharger oil return line OK?

→ Yes

GO to ch. "Fuel supply and controls", which describes further diagnosis of blue smoke. See Section 303-04A / 303-04B / 303-04C / 303-04D / 303-04E / 303-04F / 303-04G for more information.

→ No

INSTALL a new turbocharger oil return line. CHECK the system is working properly.

C1: CHECK TURBINE BYPASS VALVE ACTUATOR CONTROL PIPING FOR CLOCKAGE

1 Remove the turbine bypass valve actuator control piping.

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

• Is there an indication?

→ Yes

INSTALL a new turbine bypass valve actuator control line. CHECK the system is working properly.

→ No

Go to C2.

C2: CHECK FOR LEAKAGE OF TURBINE BYPASS VALVE DIAPHRAGM ACTUATOR.

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

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

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

• Does the pump hold a vacuum?

→ Yes

Go to C3.

→ No

INSTALL a new turbocharger. For more information, refer to Turbocharger - 75 HP Diesel Vehicles. or 90 hp available in this section. CHECK the system is working properly.

C3: BOOST PRESSURE CHECK

NOTE: Boost pressure is factory set and cannot be adjusted.

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

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

3 Raise engine speed to 3000 rpm and observe readings.

• Is the boost pressure less than 0.5 bar?

→ Yes

CHECK the fuel system. See Section 303-04A / 303-04B / 303-04C / 303-04D / 303-04E / 303-04F / 303-04G for more information.

→ No

INSTALL a new turbocharger. For more information, refer to Turbocharger - 75 HP Diesel Vehicles. or 90 hp available in this section. CHECK the system is working properly.

D1: CHECK THE VACUUM LINE OF THE VACUUM DIAPHRAGM UNIT FOR CLOCKAGE

1 Disconnect the vacuum line from the vacuum diaphragm assembly.

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

3 Operate 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 assembly. CHECK the system is working properly.

D2: CHECK THE VACUUM DIAPHRAGM UNIT FOR LEAKAGE

1 Install the special tool on the vacuum diaphragm assembly.

2 Operate the hand vacuum pump and observe the readings.

• Is the pump holding vacuum?

→ Yes

Go to D3.

→ No

INSTALL a new turbocharger. For more information, refer to Turbocharger - 115 HP Diesel Vehicles. available in this section. CHECK the system is working properly.

D3: CHECKING VACUUM DIAPHRAGM UNIT ACTUATOR MOVEMENT

1 Install the special tool on the diaphragm vane positioner.

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

• Does the drive rod of the vacuum diaphragm unit move within 9 - 11 mm?

→ Yes

REFER to WDS.

→ No

INSPECT for signs of damage or evidence of foreign material on turbocharger vanes. CHECK the system is working properly.