Page 438
REPAIR INSTRUCTIONS, PART 2
If a VTG control valve is installed for
troubleshooting purposes and the problem is not
resolved, the original control valve is to be
reinstalled.
If no travel, or less than full travel was
observed when 100 psi shop air was applied
to the actuator, remove the C-clip and pin
that connect the actuator rod to the clevis on
the vane operating lever. Manually move the
operating lever through its entire range of
travel in both directions. If the lever moves
smoothly with little resistance through the
entire range of travel, the vane assembly is
mechanically OK.
If free movement of the vane operating lever is
not achieved, DO NOT pry or hammer on the
lever. Doing so will damage the lever, vanes or
both.
VTG ACTUATOR CLEVIS PIN SEIZURE
The VTG actuator rod is connected to the lever
arm clevis by a clevis pin, and the pin is secured
in place by a C-clip.
Vane position is monitored by V-MAC
®
. If vane
positioning cannot be changed by the VTG
actuator, a cut-back in engine power will result,
and a 4-5 fault code will be logged. Possible
causes of a 4-5 fault code are a seized actuator
rod clevis pin, or an attempt was made to readjust
the VTG actuator lever stop screws.
Under no circumstances should the actuator lever
stops ever be adjusted. These stop screws are
adjusted to provide proper travel of the vanes
when the turbocharger is assembled, and
attempting to readjust the screws will cause vane
damage or seizure. If readjusted stop screws are
the cause of vane sticking or seizure, the only
corrective action is replacement of the
turbocharger, resulting in a denied warranty
claim.
If a seized actuator rod clevis pin is encountered,
spray/soak the pin with penetrating oil, then
operate the VTG actuator by alternately applying
and removing 100 psi to the actuator air fitting.
DO NOT attempt to rotate the pin. The head of
the pin has a flat which will not allow the pin to be
rotated.
DO NOT exceed 100 psi, or damage to the
actuator may result.
5-111.bk Page 438 Monday, July 10, 2006 2:26 PM
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