Section 10 Chapter 17

Section 10 Chapter 17 24 Valve, 8.3 Liter Engine Air Intake System Note: All coding used in the 8.3 Liter and 9 Liter engine manuals are Cummins engine codes. These engine codes have no meaning to New Holland warranty codes and should only be used for procedure steps. 7-89460NH

24 Valve, 8.3 Liter Engine Air Intake System Page a Air Intake System Contents Air Crossover (010-019)... 7 Inspect for Reuse (010-019-007)... 7 Install (010-019-026)... 7 Remove (010-019-002)... 7 Air Inlet Connection (010-022)... 7 Install (010-019-026)... 8 Remove (010-022-002)... 7 Air Intake Manifold (010-023)... 8 Clean (010-023-006)... 9 Inspect for Reuse (010-023-007)... 9 Install (010-023-026)... 9 Preparatory (010-023-000)... 8 Remove (010-023-002)... 8 Air Intake Restriction (010-031)... 17 Measure (010-031-010)... 17 Air Intake System - General Information... 1 Air Leaks, Air Intake and Exhaust Systems (010-024)... 10 Initial Check (010-024-001)... 10 Boost Pressure (010-057)... 31 Measure (010-057-010)... 31 Charge Air Cooler (CAC) (010-027)... 15 Clean (010-027-006)... 15 Inspect for Reuse (010-027-007)... 16 Cold Starting Aid (010-029)... 16 Clean (010-029-006)... 17 Install (010-029-026)... 17 Remove (010-029-002)... 16 Flow Diagram, Air In take System... 5 Specifications... 6 Air Intake System... 6 Turbocharger (010-033)... 19 Clean (010-033-006)... 20 Inspect for Reuse (010-033-007)... 20 Install (010-033-026)... 22 Remove (010-033-002)... 19 Turbocharger Axial Clearance (010-038)... 23 Measure (010-038-010)... 23

Page b 24 Valve, 8.3 Liter Engine Air Intake System Turbocharger Blade Damage (010-039)... 24 Inspect for Reuse (010-039-007)... 24 Turbocharger Compressor Seal Leaks (010-040)... 25 Leak Test (010-040-014)... 25 Turbocharger Oil Drain Line (010-045)... 25 Clean (010-045-006)... 26 Initial Check (010-045-001)... 25 Inspect for Reuse (010-045-007)... 26 Install (010-045-026)... 26 Remove (010-045-002)... 26 Turbocharger Oil Supply Line (010-046)... 27 Initial Check (010-046-001)... 27 Inspect for Reuse (010-046-007)... 27 Install (010-046-026)... 27 Remove (010-046-002)... 27 Turbocharger Radial Bearing Clearance (010-047)... 28 Measure (010-047-010)... 28 Turbocharger Wastegate Actuator (010-050)... 29 Initial Check (010-050-001)... 29 Test (010-050-012)... 30 Turbocharger Wastegate Valve Body (010-055)... 31 Maintenance Check (010-055-008)... 31

24 Valve, 8.3 Liter Engine Air Intake System - General Information Air Intake System Page 1 Air Intake System - General Information The combustion air system on the 24 Valve, 8.3 Liter engine consists of an air cleaner, intake air piping, turbocharger, charge air piping, charge air cooler (CAC), and intake air heater. Air is drawn through the air cleaner into the compressor side of the turbocharger (1). It is then forced through the CAC piping (2) to the CAC (3), the intake air heater (if applicable), and into the intake manifold (4). From the intake manifold, air is forced into the cylinders (5) and used for combustion. The turbocharger uses exhaust gas energy to turn the turbine wheel. The turbine wheel drives the compressor impeller which provides pressurized air to the engine for combustion. The additional air provided by the turbocharger allows more fuel to be injected to increase the power output from the engine. The turbine, compressor wheels, and the shaft are supported by two rotating bearings in the bearing housing. Passages in the bearing housing direct filtered, pressurized engine oil to the shaft bearings and thrust bearings. The oil is used to lubricate and cool the rotating components. Oil then drains from the bearing housing to the engine sump through the oil drain line., CAUTION, A restricted oil drain line can cause the turbocharger bearing housing to be pressurized, causing oil to leak past the seal rings. NOTE: An adequate supply of good, filtered oil is very important to the life of the turbocharger. Make sure that a high quality oil is used and that it and the oil filter are changed according to maintenance recommendations.

Air Intake System - General Information 24 Valve, 8.3 Liter Engine Page 2 Air Intake System, CAUTION, The turbocharger is a performance part and must not be tampered with. The wastegate bracket is an integral part of the turbocharger. Tampering with the wastegate components can reduce durability by increasing cylinder pressure and thermal loading due to incorrect inlet and exhaust manifold pressure., CAUTION, Poor fuel economy and failure to meet regulatory emissions laws may result. Increasing the turbocharger boost will not increase engine power. Wastegated turbochargers are used to optimize performance. The wastegated design allows maximum boost to be developed quickly while ensuring that the turbo does not overspeed at higher engine rpm's. Wastegate operation is controlled by an actuator that senses compressor pressure and balances it against a preset spring load. The wastegate valve is located in the turbine inlet passage. When open, it diverts a portion of the exhaust gas away from the turbine wheel, thereby controlling the shaft speed and boost. Malfunctioning Turbocharger Failure of the internal components of the turbocharger can reduce its effectiveness and also cause excessive smoke and low power. A bearing failure can produce friction which will slow the speed of the rotor assembly. Failed bearings can also allow the blades of the rotor assembly to rub the housings, thus reducing the rotor assembly speed. Malfunctioning turbocharger wastegate failure or miscalibration of the turbocharger wastegate can result in excessively high or low boost pressures. Low boost pressures can cause excessive smoke and low power. High boost pressures can cause major engine damage. Lubricating Oil Consumption and Leaks Engine lubricating oil is used to lubricate the bearings and provide some cooling for the turbocharger. The lubricating oil supplied to the turbocharger through the supply line is at engine operating pressure. A return line connected to the bottom of the turbocharger routes the lubricating oil back to the engine lubricating oil pan.

24 Valve, 8.3 Liter Engine Air Intake System - General Information Air Intake System Page 3 Seal rings are used on each end of the rotor assembly. The primary function of the seals is to prevent exhaust gases and compressed air from entering the turbocharger housing. Lubricating oil leakage from the seals is rare, but it can occur. NOTE: Excessive crankcase pressure will not allow the oil to drain from the turbocharger. This will load the bearing housing and allow lubricating oil to leak past the compressor seals and into the engine. A restricted or damaged lubricating oil return line will cause the turbocharger housing to be pressurized, causing lubricating oil to migrate past the seals. Additionally, high intake or exhaust restrictions can cause a vacuum between the compressor and the turbocharger housing resulting in oil leaking past the seals. NOTE: If this occurs, it is necessary to flush the charge air cooler to clean oil from the intake system. Refer to Procedures 010-027 and 010-033. Turbocharger Noise It is normal for the turbocharger to emit a whine sound that varies in intensity depending on engine speed and load. The sound is caused by the very high rotational speed of the rotor assembly and the method used to balance the rotor assembly during manufacturing. Consequently, the sound will be more audible at full speed. If possible, operate the engine at full speed to verify the noise level.

Air Intake System - General Information 24 Valve, 8.3 Liter Engine Page 4 Air Intake System Leaks in the air system intake and/or exhaust components can produce excessive engine noise. Leak noise is typically a high pitched whine or sucking sound. Check for leaks in the intake and exhaust system. Check to make sure all hose clamps are tight. Refer to Procedure 010-024. Lower pitch sounds or rattles at lower engine speeds can indicate debris in the system or that the rotor assembly is touching the housings. Remove the turbocharger inlet and check for foreign objects. If suspect, check for turbocharger blade damage and bearing clearance. Refer to Procedures 010-038, 010-039, and 010-047. If leaks, blade damage, or improper clearances are found, replace the turbocharger. Refer to Procedure 010-033. Engines can use a chassis-mounted charge air cooler to improve engine performance and reduce emissions. This system also uses large diameter piping to transfer the air from the engine turbocharger to the CAC, then returns the air from the CAC to the engine intake manifold.

24 Valve, 8.3 Liter Engine Flow Diagram, Air In take System Air Intake System Page 5 Flow Diagram, Air In take System 1. Intake Air Inlet to Turbocharger 2. Turbocharger Air to Charge Air Cooler 3. Charge Air Cooler 4. Intake Manifold (Integral Part of Cylinder Head) 5. Intake Valve

Specifications 24 Valve, 8.3 Liter Engine Page 6 Air Intake System Air Intake System Specifications Maximum Intake Restriction (Clean Air Filter Element)... 254 mm H 2 O [10.0 in H 2 O] Maximum Intake Restriction (Dirty Air Filter Element)... 635 mm H 2 O [25.0 in H 2 O]

24 Valve, 8.3 Liter Engine Air Crossover (010-019) Air Intake System Page 7 Air Crossover (010-019) Remove (010-019-002) 8 mm or Screwdriver Loosen the hose clamps and position the crossover tube so that it can be removed. Remove the tube. Inspect for Reuse (010-019-007) Check the crossover tube for cracks, holes, and worn sections. Replace with a new hose and clamps if necessary. Install (010-019-026) 8 mm or Screwdriver Install the crossover tube and clamps in the reverse order of removal. Tighten the clamps. Torque Value: 5 N m [44 in-lb] Air Inlet Connection (010-022) Remove (010-022-002) 8 mm Loosen air inlet clamps. Remove the air inlet connection.

Air Intake Manifold (010-023) 24 Valve, 8.3 Liter Engine Page 8 Air Intake System Install (010-019-026) Install the air inlet connection. Tighten air inlet clamps. Run engine and check for leaks. Air Intake Manifold (010-023) Preparatory (010-023-000) Disconnect the cold starting aid, if used. Remove the cooler air crossover tube, if used. Disconnect the charged air cooler hose, if used. Remove the air intake connection. Remove (010-023-002) Remove the injector supply lines. Refer to Procedure 006-051. Remove the mounting capscrews and the intake cover. Tape off the intake manifold opening to prevent debris from entering the intake system. NOTE: Be sure not to tape over the entire manifold edges so that the surface can be cleaned.

24 Valve, 8.3 Liter Engine Air Intake Manifold (010-023) Air Intake System Page 9 Clean (010-023-006) Clean the sealing surfaces. Keep the gasket material and any other material out of the air intake. Inspect for Reuse (010-023-007) Remove the tape. Inspect the intake manifold for cracks or other damage. NOTE: When inspecting the intake manifold for oil or debris from an air system failure, also inspect the cylinder head for oil and debris. Install (010-023-026) Install the cover with intake air heater (if equipped) and a new gasket. Torque Value: 24 N m [18 ft-lb] NOTE: Some capscrews shared with fuel line braces. Install the injector supply line. Refer to Procedure 006-051.

Air Leaks, Air Intake and Exhaust Systems (010-024) 24 Valve, 8.3 Liter Engine Page 10 Air Intake System Install the air intake connections, including new gaskets. Connect the charge air cooler hose. Install the air crossover tube. Air Leaks, Air Intake and Exhaust Systems (010-024) Initial Check (010-024-001) Leaks in the intake air system are most commonly identified by: 1. Inspection of piping for cracked or loose clamps. 2. Applying a solution of soapy water in the suspected area and inspecting for bubbles. 3. Listening for high pitch whining or sucking sound in the suspected area., CAUTION, Engine intake air must be filtered to prevent dirt and debris from entering the engine. If intake air piping is damaged or loose, unfiltered air will enter the engine and cause premature wear.

24 Valve, 8.3 Liter Engine Air Leaks, Air Intake and Exhaust Systems (010-024) Air Intake System Page 11 Inspect the inlet air piping for cracked hoses and damaged or loose clamps. Operate the engine at high idle and use a solution of soapy water to spot intake air leaks. If an air leak exists, the soap bubbles will be drawn in with the air. Replace damaged pipes and tighten loose clamps to make sure the air inlet system does not leak. Torque Value: 8 N m [71 in-lb] Check for corrosion of the inlet system piping under the clamps and hoses. Corrosion can allow corrosive products and dirt to enter the intake system. Disassemble and clean as required. Pressure Side Intake System Leaks in the intake system will reduce the amount of air to the cylinders during engine operation and decrease engine performance. Operate the engine at full throttle and rated rpm with maximum load. Apply soapy water solution to sealing surfaces and inspect for bubbles. Bubbles should be easy to detect.

Air Leaks, Air Intake and Exhaust Systems (010-024) 24 Valve, 8.3 Liter Engine Page 12 Air Intake System Leaks may also be found at the turbo outlet connection. Inspect for damage, replace sealing o-ring, and tighten loose clamps. Leaks may also be found at the turbo outlet connection. Inspect for damage, replace sealing o-ring, and tighten loose clamps. Torque Value: 8 N m [71 in-lb] Any Charge Air Cooler Tubing or Connecting Hoses Inspect the hose and tubing for damage. Tighten loose clamps. Torque Value: 8 N m [71 in-lb] Intake Manifold Connection Inspect for damage. Tighten loose clamps. Replace the gasket. Refer to Procedure 010-023.

24 Valve, 8.3 Liter Engine Air Leaks, Air Intake and Exhaust Systems (010-024) Air Intake System Page 13 Intake Manifold Inspect for damage. Replace the gasket. Refer to Procedure 010-023. Wastegate Capsule/Plumbing Inspect for damage. Compressor Housing Sealing Surface Inspect for damage. Clean surface. Exhaust System Leaks in the exhaust system will cause the turbo to operate at a lower speed, reducing the amount of air going to the cylinders during engine operation.

Air Leaks, Air Intake and Exhaust Systems (010-024) 24 Valve, 8.3 Liter Engine Page 14 Air Intake System Operate the engine at full throttle and rated rpm with maximum load. Leaks can be identified by noise, soapy water, or discoloration caused by the escaping hot gases. Inspect the exhaust manifold gaskets for leaks. Inspect the turbocharger mounting gaskets for leaks. Inspect the turbine housing sealing surface for leaks.

24 Valve, 8.3 Liter Engine Charge Air Cooler (CAC) (010-027) Air Intake System Page 15 Operate the engine at full throttle and rated rpm with maximum load. Listen and inspect again for leaks. Charge Air Cooler (CAC) (010-027) Clean (010-027-006) If the engine experiences a turbocharger failure or any other occasion where oil or debris is put into the charge air cooler (CAC), the CAC must be cleaned. Remove the CAC piping and CAC from the vehicle., CAUTION, Do not use caustic cleaners to clean the CAC. Damage to the CAC will result. Flush the CAC internally with solvent in the opposite direction of normal air flow. Shake the CAC and lightly tap on the end tanks with a rubber mallet to dislodge trapped debris. Continue flushing until all debris or oil is removed (i.e., the water runs clear). NOTE: Make sure that the tubes are in the vertical direction when flushing. If the debris can not be totally removed from the CAC, the CAC must be replaced. After the CAC has been thoroughly cleaned of all oil and debris with solvent, wash the CAC internally with hot soapy water to remove the remaining solvent. Rinse thoroughly with clean water., CAUTION, The CAC must be rinsed, dried, and free of solvent, oil, and debris, or engine damage will result. Blow compressed air through the inside of the CAC in the opposite direction of normal air flow until the CAC is dry internally.

Cold Starting Aid (010-029) 24 Valve, 8.3 Liter Engine Page 16 Air Intake System Inspect for Reuse (010-027-007) Inspect the CAC for cracks, holes, or damage. Inspect the tubes, fins, and welds for tears, breaks, or other damage. If any damage causes the CAC to fail the air leak check, the CAC must be replaced. Refer to Procedure 010-024. Install the CAC and CAC piping on the vehicle. Always clean and inspect the CAC piping and hoses prior to installation. Cold Starting Aid (010-029) Remove (010-029-002) If equipped, remove charge air cooler (CAC) plumbing. Disconnect grid heater wiring. Remove the air intake connection. Remove high pressure fuel lines. Refer to Procedure 006-051. Remove intake air heater assembly. Refer to Procedure 010-022. If the grid heater is to be removed for any length of time, apply tape over the hole to keep debris out of the air intake.

24 Valve, 8.3 Liter Engine Air Intake Restriction (010-031) Air Intake System Page 17 Clean (010-029-006) Clean the grid heater sealing surfaces. Clean the intake cover sealing surface. Clean the air intake connection sealing surface. Keep the gasket material and any other material out of the cylinder head intake manifold. Install (010-029-026) Install the grid heater, high pressure fuel lines, intake connection, and new gaskets. Refer to Procedures 010-022 and 006-051. Torque Value: 24 N m [18 ft-lb] Connect grid heater wiring. Install CAC plumbing. Refer to Procedure 010-027. Run the engine and check for leaks. Air Intake Restriction (010-031) Measure (010-031-010) Install a vacuum gauge or water manometer in the intake air piping. The gauge adapter must be installed at a 90 degree angle to the air flow in a straight section of pipe, one pipe diameter before the turbocharger.

Air Intake Restriction (010-031) 24 Valve, 8.3 Liter Engine Page 18 Air Intake System Operate the engine at full throttle and rated rpm with maximum load. Record the data on the gauge or manometer. Inlet Air Restriction mm H 2 O in H 2 O 63.5 MAX 25.0 If restriction exceeds specifications: Replace or clean the air filter element. Refer to the operators manual instructions. Inspect the intake piping for damage. Remove the test equipment.

24 Valve, 8.3 Liter Engine Turbocharger (010-033) Air Intake System Page 19 Turbocharger (010-033) Remove (010-033-002) Remove the intake and exhaust pipes from the turbocharger. Remove the oil supply line from the turbocharger. Remove the oil drain line from the turbocharger. Remove the v-band clamp, discharge elbow and o-ring from the turbocharger compressor discharge outlet. Remove the four turbocharger mounting nuts. Remove the turbocharger and gasket. NOTE: If the turbocharger is not to be immediately replaced, cover the opening to prevent any material from falling into the manifold.

Turbocharger (010-033) 24 Valve, 8.3 Liter Engine Page 20 Air Intake System Clean (010-033-006) Clean the turbocharger and exhaust manifold gasket surfaces. Inspect for Reuse (010-033-007) Inspect the turbocharger and exhaust manifold gasket surfaces, and mounting studs for cracks and damage. Inspect the turbine and compressor housings. If cracks that go all the way through the outer walls are found, the housing 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. Cracks in the mounting flange longer than 15 mm [0.6 in] are not acceptable.

24 Valve, 8.3 Liter Engine Turbocharger (010-033) Air Intake System Page 21 Cracks of any length that reach mounting holes are not acceptable. Two cracks must be separated by at least 6.4 mm [0.25 in]. Cracks in the divider are acceptable only if they are separated by at least 12.5 mm [0.50 in]. NOTE: If the engine experiences a turbocharger failure or any other occasion where oil or debris is put into the charge air system, the charge air system must be inspected and cleaned. Refer to Procedures 010-027 and 010-023.

Turbocharger (010-033) 24 Valve, 8.3 Liter Engine Page 22 Air Intake System Install (010-033-026) 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. The torque values given have been established using antiseize compound as a lubricant. Torque Value: 45 N m [33 ft-lb] Install the discharge elbow, v-band clamp, and new o-ring seal on the turbocharger compressor discharge outlet. Tighten the clamp. Torque Value: 8 N m [71 in-lb] Install and tighten the turbocharger oil drain line. Torque Value: 27 N m [20 ft-lb] Lubricate the bearings by pouring 50 to 60 cc [2.0 to 3.0 oz] of clean 15W-40 engine oil into the turbocharger oil supply line fitting. Install and tighten the turbocharger oil supply line. Torque Value: 20 N m [15 ft-lb]

24 Valve, 8.3 Liter Engine Turbocharger Axial Clearance (010-038) Air Intake System Page 23 Rotate the compressor housing to fit intake pipes, if necessary. Use the snap ring to make necessary adjustments. Install the intake pipe and tighten the clamp. Install the exhaust pipe and tighten the clamp. Torque Value: 8 N m [71 in-lb] Operate the engine and check for air leaks. Turbocharger Axial Clearance (010-038) Measure (010-038-010) Remove exhaust and intake piping. Push the rotor assembly away from the gauge. Set the gauge on zero (0). Push the rotor assembly toward the gauge and record the reading. Axial Clearance mm in 0.038 MIN 0.0015 0.089 MAX 0.0035 Replace the turbocharger if the clearance does not meet the specifications. Refer to Procedure 010-033. Install the exhaust pipe and tighten the clamp. Install the intake pipe and tighten the clamp. Torque Value: 8 N m [71 in-lb]

Turbocharger Blade Damage (010-039) 24 Valve, 8.3 Liter Engine Page 24 Air Intake System Turbocharger Blade Damage (010-039) Inspect for Reuse (010-039-007) Remove the intake pipe from the turbocharger. Inspect the turbocharger compressor impeller blades for damage. Replace the turbocharger if damage is found. Refer to Procedure 010-033. If the compressor impeller is damaged, inspect the intake piping and filter element for damage. Repair any damage before operating the engine. Remove the exhaust pipe from the turbocharger. Inspect the turbine wheel for damage. Replace the turbocharger if damage is found. Refer to Procedure 010-033. Install the intake pipe and tighten the clamp. Install the exhaust pipe and tighten the clamp. Torque Value: 8 N m [71 in-lb]

24 Valve, 8.3 Liter Engine Turbocharger Compressor Seal Leaks (010-040) Air Intake System Page 25 Turbocharger Compressor Seal Leaks (010-040) Leak Test (010-040-014) Remove the air intake and CAC piping from the turbocharger. Inspect the 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. If oil is present only in the discharge side, install the air intake and CAC piping. Check for intake restriction. Refer to Procedure 010-031. If no intake restriction is found, replace the turbocharger. Refer to Procedure 010-033. NOTE: If the engine experiences a turbocharger failure or any other occasion where oil is put into the charge air system, the charge air system must be inspected and cleaned. Refer to Procedures 010-027 and 010-023. Turbocharger Oil Drain Line (010-045) Initial Check (010-045-001) Inspect the turbocharger oil drain line for oil leaks or damage. Repair as necessary.

Turbocharger Oil Drain Line (010-045) 24 Valve, 8.3 Liter Engine Page 26 Air Intake System Remove (010-045-002) Remove the capscrews from the oil drain tube. Pull the drain line out of the drain line boss. Clean (010-045-006) Clean the gasket sealing surfaces (first frame). Clean the o-ring seating bore and make sure it is free of dirt and debris (second frame). Inspect for Reuse (010-045-007) Inspect the line for cracks, wear, and damage. Inspect the o-ring for fretting and cracking. Replace if necessary. Check the rubber section of the drain line for deterioration. Install (010-045-026) Apply a thin film of oil to the drain line o-rings. Push the drain line into the drain line boss. Be sure both o-rings are completely seated in the bore. Install the drain line capscrews with a new gasket. Operate the engine and check for leaks.

24 Valve, 8.3 Liter Engine Turbocharger Oil Supply Line (010-046) Air Intake System Page 27 Turbocharger Oil Supply Line (010-046) Initial Check (010-046-001) Inspect the line for oil leaks or damage. Replace if necessary. Remove (010-046-002) Remove the oil supply line from the turbo bearing housing (1). Remove the oil supply line from the oil filter head (2). Inspect for Reuse (010-046-007) Inspect the line for cracks, wear, and damage. Inspect o-rings for cracking and fretting. Replace if necessary. Install (010-046-026) Apply a thin film of oil to the o-ring seals. Fill the turbo oil inlet with clean oil. Install a line at both the filter head and the turbo bearing housing, then hand tighten. Tighten the line to final torque. Torque Value: 24 N m [18 ft-lb]

Turbocharger Radial Bearing Clearance (010-047) 24 Valve, 8.3 Liter Engine Page 28 Air Intake System Operate the engine and check for leaks. Turbocharger Radial Bearing Clearance (010-047) Measure (010-047-010) Remove the intake and exhaust pipes from the turbocharger. Use a narrow blade or a wire type feeler gauge to measure the clearance between the compressor wheel and housing. Gently push the compressor wheel toward the compressor housing and gauge. Record this clearance. With the feeler gauge in the same location, gently push the compressor wheel away from the compressor housing and measure the clearance between the compressor wheel and housing. Record this clearance.

24 Valve, 8.3 Liter Engine Turbocharger Wastegate Actuator (010-050) Air Intake System Page 29 Subtract the smaller clearance from the larger clearance. This is the radial bearing clearance. Radial Bearing Clearance mm in 0.15 MIN 0.006 0.64 MAX 0.025 Replace the turbocharger if the radial bearing clearance does not meet the specifications. Refer to Procedure 010-033. Install the intake pipe and tighten the clamp. Install the exhaust pipe and tighten the clamp. Torque Value: 8 N m [71 in-lb] Operate the engine and check for leaks. Turbocharger Wastegate Actuator (010-050) Initial Check (010-050-001) 24 Valve, 8.3 Liter engines are equipped with wastegated turbochargers to limit the peak boost level and increase engine response at low rpm. The integral wastegate line takes boost from the turbo compressor outlet to the wastegate capsule. Inspect the integral wastegate actuator hose for cracks or holes. Replace the hose if damaged.

Turbocharger Wastegate Actuator (010-050) 24 Valve, 8.3 Liter Engine Page 30 Air Intake System 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. Test (010-050-012) NOTE: In some applications the turbocharger must be removed to test the wastegate actuator. Refer to Procedure 010-033. 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 should move approximately 0.5 to 1.04 mm [0.20 to 0.41 in] without any sticking or air leakage. NOTE: No air should be heard such as leak noise through a functional wastegate capsule. NOTE: A small amount of travel when air pressure is first applied is normal. The tolerance is being removed from the system. Replace the turbocharger if no movement of the actuator rod and lever is detected.

24 Valve, 8.3 Liter Engine Turbocharger Wastegate Valve Body (010-055) Air Intake System Page 31 Turbocharger Wastegate Valve Body (010-055) Maintenance Check (010-055-008) Inspect the lever pin. Replace the turbine housing assembly if worn excessively. Inspect the valve and valve seat for cracks or erosion. Replace the turbine housing assembly if worn excessively. Boost Pressure (010-057) Measure (010-057-010) Measure boost pressure at the intake manifold by using an electronic service tool for hookup and monitoring procedures.

Boost Pressure (010-057) 24 Valve, 8.3 Liter Engine Page 32 Air Intake System