Holset HE341Ve - Cummins Turbo Technologies
Contents
1. OBD SD 0 20 30 40 50 60 70 80 90 100 11 ES l 4 6 HE341Ve Service Manual M6 x 1 8 mm Where ECM indicates a speed sensor fault and no wiring or connector problems are found refer to Speed Sensor Check and Removal for further health checks Replace sensor by refering to Speed Sensor Replacement Caution A Never remove actuator mechanism 5 bolt cover plate as this will adversely effect actuator clearance conditions Component Testing and Replacement HE341Ve Service Manual Bearing Clearance Secure the turbine housing and check the axial clearance at compressor impeller nose using a dial gauge Ensure clearance is within MIN MAX values shown on Service Data Sheet If axial clearance does not meet specification replace the turbocharger Check the radial movement at compressor impeller nose using a dial gauge Ensure movement is within MIN MAX TIR Total Indicator Reading values shown on Service Data Sheet If radial movement does not meet specification replace the turbocharger Component Testing and Replacement 4 8 HE341Ve Service Manual Position Sensor Check and Removal Where space claim allows position sensor checks and removal should be done on engine If this is not possible remove actuator by reference to Actuator Check and Removal If actuator removal is not possible remove t2. 1 2 Notes Cautions and Warnings 1 4 Installation Data 1 5 Installation Checklist sos cotorra HH er 1 6 SymMB lIS 2a ses E e eR Koss Rt de bye eee ne a DU 1 7 2 Component Identification Turbocharger Identification 2 1 Dataplate and CHRA Core of Turbocharger 2 1 Installation Options 2l 2 2 Exploded Views 2 3 Component List 2 4 Purchasable Service Tools 2 5 3 Troubleshooting and Diagnosis Fault Finding Chart 3 1 4 Component Testing and Replacement Service Tools o ve te id tussi ee eet 4 1 On Engine Checks 4 3 Bearing Clearance 4 8 Position Sensor Check and Removal 4 9 Position Sensor Replacement 4 11 Actuator Check and Removal 4 12 VG Mechanism Check 4 14 Remote Actuator Check iea ocean ea 4 15 Actuator Replacement 4 16 Speed Sensor Check and Removal 4
3. Turbocharger Speed Actuator Position 4 9 HE341Ve Service Manual Apply system voltage to fitted or remote actuator motor through on off switch Confirm travel is within permissible range shown in Service Data Sheet Warning Keep fingers away from rod during actuation sequence M4 x 0 7 3 mm Warning Always wear safety glasses Where an electrical fault is diagnosed or correct actuation is confirmed use a socket wrench and rachet to loosen and remove 2 socket head screws Caution A Breaking the sealed fastener joints may require significant torque It is essential that the socket wrench is properly engaged to avoid inadvertent damage to connector resulting from spanner slip Extract the position sensor and refer to Position Sensor Replacement Component Testing and Replacement 4 10 HE341Ve Service Manual Component Testing and Replacement Position Sensor Replacement Position sensor kits 152 are available Warning Always wear safety glasses Ensure clamped surfaces are clean prior to inserting position sensor The sensor flange features a mechanical baulk tab to ensure correct sensor orientation First ensure o ring seal is greased and in position Engage sensor on to flatted shaft then locate flange baulk into housing face location 4 mm X 0 7 3mm New
4. e e N oO Apply system voltage to actuator motor through on off switch Switch voltage to retract and extend actuator rod Check actuation cycle can be completed in 5 gt ADO seconds II Say Warning A Keep fingers away from rod during actuation sequence RO If any of three test results are outside specified value replace actuator by refering to Actuator Replacement ROO 10 20 30 40 5 4 15 HE341Ve Service Manual Actuator Replacement Warning A Always wear safety glasses Actuator service kits are available 121 Used actuators may be refitted depending on ECM fault diagnostics and confirmatory turbocharger investigations using the processes set out in this Service Manual Actuator fitting kit 122 is recommended when refitting used actuator Apply high temperature grease eg Molycote to cross shaft pin Caution A Ensure cross shaft pin grease applicator and pivot block bore are clean Position pivot block on pin ensuring it is in line with crank arm Ensure actuator rod is in mid travel This assists with insertion of pivot block through aperture in actuator mounting face and location into mating slot in actuator rod Note Always check VG cross shaft movement prior to refitting or replacing actuator Ensure actuator fasteners and tapped holes in bearing housing are clean and dry before inserting fasteners Caution A It is
5. HE341Ve Service Manual Apply system voltage to actuator motor through on off switch If actuator travel is outside range shown in Service Data Sheet remove actuator Warning A Keep fingers away from rod during on off actuating sequence Warning Always wear safety glasses Actuator Removal M8 x 1 25 10 mm Where it is not possible to remove actuator coverplate on engine remove turbocharger from engine in accordance with engine service manua l 4 bolt coverplate and gasket removal provides access to 3 actuator caphead fasteners Use socket wrench and ratchet to loosen and extract screws whilst holding actuator in position Carefully slide actuator rod from slot location with pivot block Remove actuator Warning A Do not use actuator motor as a lifting handle particularly when actuator is assembled to turbocharger Note With actuator removed it is logical to carry out VG mechanism check before continuing with actuator diagnostic Component Testing and Replacement 5 gt e 3 J AG gt gt DO gt R SA A S 4 13 HE341Ve Service Manual VG Mechanism Check With actuator removed it is possible to check that pivot block if free to rotate and move axially on cross shaft crankpin If pivot block is seized or if force is required to move pivot block on crankpin replace turbocharger If pivo
6. 2104C specification Improved life can be obtained by using super high performance diesel SHPD oils particularly in industrial applications which use extended oil drain periods Normal oil temperature is 95 5 C 203 9 F It should not exceed 120 C 248 F under any operating condition Any pre lube oil must be clean and meet the minimum CD classification The orientation of turbine housing bearing housing and compressor cover is fixed according to application During installation do not attempt to rotate these components as it may affect the operation of the variable geometry actuating mechanism and may void warranty Inclined turbocharger installation is not recommended If an installed angle is necessary oil inlet centreline must be 10 degrees from vertical and rotor centreline 5 degrees from horizontal Holset permits oil return pipes to decline at an overall angle of not less than 30 degrees below horizontal All turbocharger applications require a pipe of internal diameter greater than 19 mm which has integrated connectors To ensure oil returns into the engine under all operating conditions the return connection into the engine sump must not be submerged and the outlet flange of the turbocharger must be 50 mm above the maximum oil level of the engine sump pan Crankcase pressure should be limited ideally to 0 8 kPa 0 12 Ibf in but 1 4 kPa 0 20 Ibf in can be accepted by reference to Holset Oil pressure of 150
7. Common tools found in mechanic s tool box not included 4 1 HE341Ve Service Manual Component Testing and Replacement Service Tools H The following special tools are recommended to perform procedures in this manual The use of these tools is shown in the appropriate procedure These tools can be purchased from your local Authorised Repair Location Part No Tool Description Tool Illustration Multi meter Vehicle Battery Supply Service Test Equipment TURBOCHARGERS Caution A All Service and Maintenance settings are shown in Holset s Service Data Sheet It is essential that these settings are used Common tools found in mechanic s tool box not included 4 2 HE341Ve Service Manual On Engine Checks Component Testing and Replacement 0 H Variable geometry turbochargers have potential oil gas coolant and air leak paths They are fitted with sensors and an actuator which contain sensitive components When checking and correcting leaks it is essential that good practice and the correct tools are used to avoid damaging the turbocharger Bearing housing seals and adapter kits 123 are available Oil Leakage M12 x 1 5 Warning The oil inlet is pressurized and no service action should be taken with the engine running l SA Replacement seals and adapters should be fitted without sealant as this can contaminate the oil Torque tighten adapter to value specified by engine manufacturer pa
8. It is important to avoid kinked or worn pipes during servicing and subsequent operation M8 x 1 25 Warning A ES Outlet oil is hot and no service action should be taken with the engine running a g gt Replacement gaskets should be fitted without sealant as this can contaminate the oil Torque tighten flange fasteners to value specified by engine manufacturer All outlet pipes should be free flowing without kinks and gs sharp bends and decline at an overall angle not less than 30 degrees below the horizontal M6 x 1 0 8 mm The variable geometry VG cross shaft is sealed against oil leakage by a spring backed oil seal Leakage can be detected by removing the 4 bolt actuator coverplate If leak is detected remove and replace turbocharger Caution A Seals must be replaced using specialised equipment Do not attempt to replace in service o Qe Coolant Leakage M16 x 1 5 Repair bearing housing coolant leaks by refitting replacing inlet and outlet adapters Torque tighten adapters to value specified by engine manufacturerer OP HA Where housing threads are damaged replace EN turbocharger D on Caution A Do not use sealant as this may affect performance of o ring seals 0 4 3 HE341Ve Service Manual Component Testing and Replacement 0 H M10 x 1 0 16 mm Repair actuator coolant leakage by re fitting replacement of cool
9. 19 Speed Sensor Replacement 4 20 6 Service Data Sheets HX Range Service Data Sheets 6 1 HE341Ve Service Manual Introduction About the Manual The procedures in this manual were developed to instruct in the correct overhaul of the Holset HE341Ve turbocharger for optimum performance and minimum maintenance operation How to Use the Manual The manual is split into sections designed to provide service information in a logical sequence The manual contains links to help the user navigate between relevant sections Users who are unfamilier with navigating in PDF documents are refered to Navigating in PDF documents in the Adobe Acrobat Reader help file Contents is an interactive page with links to all the sections It can be accessed from any page in the manual by clicking this icon Section 1 defines the layout of the manual introduces the reader to the operation of the turbocharger and presents important installation guidelines Sections 2 3 and 4 concentrate on Turbocharger Component Identification Troubleshooting and Diagnosis Component Testing and Replacement Section 5 identifies the Service and Overhaul procedures to be followed in the unlikley event of a major turbocharger malfunction This section is not available for the HE341V e turbocharger range at the present time Section 6 quantifies build data to ensure the turbocharger will co
10. diagnostics for possible fault code data To avoid feedback error to ECM 0 0 0 000 ee always disconnect and reconnect actuator motor and position sensor in correct sequence Disconnect motor before position sensor Reconnect position sensor before motor If actuator rod travel restricted ensure pivot block moves freely on cross shaft pin If no axial or rotary movement or if force required to move block then replace turbocharger No speed signal eo e e e Refer to ECM diagnostics for possible fault code data Check sensor connections If pin resistance measurement is incorrect replace sensor Where sensor may have been overheated check ECM diagnostic fault codes and if necessary replace sensor Intermittent or noisy speed signal Refer to ECM diagnostics for possible fault code data Check sensor with multimeter If e e 0 0 e e either resistance measurement is incorrect replace sensor Where sensor may have been overheated check ECM diagnostic fault codes and if necessary replace sensor No boost pressure signal P2 If the ECM diagnoses a boost pressure signal error refer to engine manual e 0 0 e No air inlet temperature signal T2 If the ECM diagnoses an ai inlet temperature signal error refer to engine manual e e 0 0 e 3 3 HE341Ve Service Manual Troubleshooting and Diagnosis Fault Finding Chart variable Geometry E 2 D 3 o o 92 x E 2 o 0 P e 5 D 2 cu gt LS 3 o LL E
11. electrical system and key on calibration sequence to check rod travel of remote actuator is within permissible range If outside range replace actuator by refering to Actuator Replacement Caution A Detached actuator stroke is greater than stroke when attached to VG nozzle Ensure correct range is read from Service Data Sheet If actuator rod travel is within permissible range shown in Service Data Sheet check pivot block is free to rotate and move axially on cross shaft pin If pivot block is seized or if force is required to move pivot block on pin remove block and check pin for damage Replace turbocharger if damaged If pivot block is loose on pin refer to Actuator Check and Removal to check pin and pivot block hole diameters Caution A Always check pivot block for wear and refit to cross shaft pin before refitting actuator If pivot block rotates freely remove pivot block and check linear travel of VG cross shaft pin is within permissible range shown in Service Data Sheet Caution A Use moderate hand force only to rotate cross shaft If pin shows no resistance to motion or does not travel within permissible range replace turbocharger If pin travels within permissible range replace actuator by refering to Actuator Replacement Note Always check VG cross shaft movement prior to refitting or replacing actuator Component Testing and Replacement SA ap MIES gt gt Q te
12. genau befolgt werden da ein Nichtbeachten zu Personensch den oder t dlichen Verletzungen f hrt ACHTUNG Falls Unterhaltungs und Wartungsverfahren nicht genau beachtet werden kann der Turbolader dadurch besch digt oder zerst rt werden AUSBAU bzw ZERLEGEN EINBAU bzw ZUSAMMENBAU INSRPEKTION erforderlich Teil oder Baugruppe REINIGEN DIMENSION oder ZEITMESSUNG Teil oder Baugruppe LEN WERKZEUGGR SSE wird angegeben ANZUG auf vorgeschriebenes Drehmoment erforderlich Sicherstellen da die AUSWUCHTMARKEN an der Rotor Baugruppe richtig ausgerichtet sind Elektrische MESSUNG DURCHF RHREN Weitere Informationen an anderer Stelle bzw in anderen Handb chern Schutzkleidung mu immer getragen werden Deutet an da Teile schwer sein k nnen Website Verzeichnis mit Ihrem n chsten Holset H ndler Gehe zu Inhalt 1 7 HE341Ve Service Manual Introduction Symbols English The following group of symbols have been used in this manual to help communicate the intent of the instructions When one of the symbols appears it conveys the meaning defined below A Ri S RY S m amp WARNING Serious personal injury or extensive property damage can result if the warning instructions are not followed CAUTION Minor personal injury can result or a part an assembly or the engine can be damaged if the caution instructions are not followed Indicates a REMOVAL or DISASSEMBLY step Ind
13. is secure and will not leak in use Assemble any coolant pipes and check that the connections are secure without obstruction and will not leak in use Assemble the turbocharger oil inlet pipe and check that the connection is clean secure and will not leak in use Check all clamps and fasteners are correctly tightened to the torque recommended by the equipment manufacturer Make the electrical connections between VG actuator motor sensors and engine control module ECM Make any ECM checks recommended by the engine manufacturer Crank the engine WITHOUT firing until engine oil flows out of the turbocharger drain flange Assemble the oil drain pipe and check that the connection is secure without obstruction and will not leak in use Start the engine and run at idle speed for approximately 1 minute so that the oil supply system is fully operational Accelerate the engine and check that there are no leaks obstructions of air oil coolant gas under pressure Check that no hose or connection deforms under normal operation Before switching off the engine leave it running at idle speed for at least 1 minute to cool the turbine 1 6 HE341Ve Service Manual Introduction Symbols Symbole Deutsch In diesem Handbuch werden die folgenden Symbole verwendet die wesentliche Funktionen hervorheben Die Symbole haben folgende Bedeutung A Ri S RY G m amp WARNUNG Unterhaltungs und Wartungsverfahren m ssen
14. les rep res d quilibrage sur l ensemble de rotor sont align s EFFECTUER une MEASURE lectrique Se reporter un autre endroit dans ce manuel ou une autre publication pour obtenir des information plus compl tes Il faut toujours mettre v tements de protection Indique que les composants peuvent tre lourds Acc s au site Web pour trouver l agent Holset le plus proche Aller au sommaire 1 10 HE341Ve Service Manual Introduction S mbolos Portugu s Os s mbolos a seguir ser o utilizados neste manual para facilitar a comunica o das instru es e seue significados est o d scritos abaixo A A Ri S RY Sy m amp ATENC O Os procedimentos de Manutenc o ou Servicos que n o forem seguidos correctamente resultar o em ferimentos pessoais ou riscos de vida AVISO Os procedimentos de Manutenc o ou Servico que n o forem rigorosamente seguidos resultar o em danos ou destruic o do carregador turbo Indica um passe de DESMONTAGEM Indica um passo de MONTAGEM Requer inspec o LIMPE a peca ou conjunto Requer Medic o mec nica ou de tempo LUBRIFIQUE a peca ou o conjunto Indica necessidade de APERTO TORQUEAR de acordo com o especificado Assegure se de que as MARCAS DE BALANCEAMENTO do conjunto eixorotor estejam alinhadas Requer medi o EL TRICA Procure em outra se o deste manual ou em publica o par obter informa es adicionais Por favor sempre utilize
15. position sensor Reconnect position sensor before motor Check actuator wiring for bad connections Check motor pin resistance with multimeter Repair pin or wire damage by renewing connectors and leads Remove 4 bolt actuator coverplate to expose actuator rod end If actuator rod travel is within range specified by service manual recheck ECM If no rod movement replace actuator Refer to actuator rod not moving for further fault finding Actuator motor or gears noisy If actuator operates with excessive motor or gear noise replace actuator e e Position sensor fault indication e e e e o Refer to ECM diagnostics for possible fault code data To avoid feedback error to ECM always disconnect and reconnect actuator motor and position sensor in correct sequence Disconnect motor before position sensor Reconnect position sensor before motor Ensure sensor wiring for bad connections Check sensor pin resistance with multimeter Repair pin or wire damage by renewing connectors and leads If fault persists replace position Sensor If new sensor still not working check ECM Where position sensor malfunction a to affect engine operation ECM will fully open VG nozzle to enable limp home acility Position sensor nozzle open voltage outside range Refer to ECM diagnostics for possible fault code data To avoid feedback error to ECM oo e o0 9 e always disconnect and reconnect actuator motor and position sensor in correct sequence Disconnect motor before
16. restricted m Check coolant pipework and connections for damage Replace damaged fittings using oo e genuine replacement parts Refer to engine manual for flow data and service instructions coolant flow remains restricted replace turoocharger Bearing housing coolant pipework or connectors leaking X Replace damaged pipes and tighten connectors to torque specified in engine service eoo o o instructions If leak persists replace damaged fittings using genuine replacement parts and torque to specitication If leak persists replace turbocharger Bearing housing oil feed and return lines leaking Replace damaged pipes Check o ring seals and gaskets Replace if necessary Tighten 0 0 eo e connectors to torque specified in engine service instructions If leak persists replace damaged fittings using gen ine replacement parts and torque to specification If leak persists replace turbocharger 3 4 HE341Ve Service Manual Component Testing and Replacement Service Tools H The following special tools are recommended to perform procedures in this manual The use of these tools is shown in the appropriate procedure Part No Tool Description Tool Illustration Torque Wrench Dial Gauge and Dial Gauge Adapter Steel Rule Vernier Caliper Allen Key Stopwatch Caution A All Service and Maintenance settings are shown in Holset s Service Data Sheet It is essential that these settings are used
17. to the fixed shroud plate This movement varies the area through which exhaust gas enters the turbine wheel blades LF Actuator Control Signal Engine Speed Engine Control Module ECM Exhaust Outlet Pressure Throttle Demand P Contains pre set data on airflow requirements for any fuel quantity injected at any engine speed with built in safety features for excessive boost smoke or turbocharger speed Inlet Manifold Pressure amp Temperature Turbocharger Speed Exhaust Manifold Pressure Actuator Position Ambient Pressure and Temperature Eee 1 3 HE341Ve Service Manual Introduction Notes Cautions and Warnings Notes Cautions and Warnings are used in this manual to emphasise important or critical instructions Note Information which is essential to highlight Caution A Maintenance or Service procedures which if not strictly followed will result in damage or destruction of the turbocharger Warning A Maintenance or Service procedures which if not correctly followed will result in personal injury or loss of life Note Holset turbochargers can be remanufactured using recovered parts Where it is necessary to dispose of components or whole turbochargers an environmentally responsible process such as recycling should be used with due regard to local laws Note Holset Service receives many turbocharger returns that are
18. 2 2 co ND 5 CCC ES D 2 1 2 E e 5 90 cy KH 2 U 2 95 pa 2 3 wx CQ ous D E ke 08 g gt Iz o o S o m o gt J 2 BD E 8 00 D a gt E lt a o x o o a 8 E T A IN RE AE III ES E O A O E O O O O E O E O O E E w ju yu OO O TS ar 3 0 1 2 o o Actuator coolant circuit restricted m ele e Check coolant pipework and connections for damage Replace damaged fittings using genuine replacement parts Refer to engine manual for flow data and service instructions coolant flow remains restricted replace actuator Actuator coolant pipework or connectors leaking Replace damaged pipes and tighten connectors to torque specified in engine service e e e instructions If leak persists replace damaged actuator fittings using genuine replacement parts and torque to specification If leak persists replace actuator Actuator coolant joint leaking A If coolant leaks from 5 bolt actuator mechanism coverplate joint replace actuator Never 0 0 e e remove 5 bolt coverplate as this will adversely affect actuator clearance conditions Coolant ingress into actuator bracket cavity Replace actuator oo e e Oil ingress into actuator bracket cavity Replace turbocharger 0 0 e e Air leakage from speed sensor Check o ring seal and replace if necessary Refit sensor and torque fastener to value in 0 0 0 00 service manual If leak persists replace sensor If leak continues replace turbocharger Bearing Housing coolant circuit
19. EPI Equipamento de Protecao Individual Indica que os componentes podem estar pesados Visite o Website para encontrar o seu Agente Holset mais perto V para Conte do 1 11 HE341Ve Service Manual Turbocharger Identification Dataplate Note Dataplates may be fitted to the DC motor of the VG actuator 126 or to the compressor housing 8 The information from the dataplate must be quoted for service and parts support HE341Ve Made in Huddersfield England Component Identif cation O Assy WARNING Any misuse or Serial unauthorised modification Customer of this turbocharger may cause damage or personal injury Use Type only as specified by Holset 0 H 35XXXXX XYYMMXXXXX HE341Ve 2 1 HE341Ve Service Manual Component Identif cation 0 H Installation Options Type A HE341Ve Service Manual Component Identif cation Exploded View HE341Ve H Note Exploded views represent a generic build standard Parts may be added or subtracted in specific applications 2 3 HE341Ve Service Manual Component Identif cation Component List HE341Ve H Item No Description Quantity 121 VG Actuator Kit comprising 1 126 VG Actuator 1 122 VG Actuator Fittings Kit comprising 1 120 Screw Cap Head 3 151 Coverplate Actuator 1 46 Gasket Coverplate 1 67 Bolt Coverplate 4 154 Pivot Block 1 152 VG Position Sensor Kit compri
20. Houser TURBOCHARGERS Copyright 2007 Cummins Turbo Technologies Ltd All rights reserved VGT Command Valve and Super MWE are trade marks of Cummins Turbo Technologies Ltd Holset and the Holset Logo are registered trade marks of Cummins Turbo Technologies Ltd Cummins and the Cummins logo are registered trade marks of Cummins Inc HE341Ve Service Manual Foreword Foreword This publication was written to assist with turbocharger installation maintenance and overhaul The specifications and procedures in this manual are based on information in effect at the time of publication Holset Service reserves the right to make any changes at any time without obligation If differences are found between your turbocharger and the information in this manual contact your local Holset approved agent The latest technology and the highest quality standards are used in the manufacture of Holset Turbochargers When replacement parts are needed we recommend using only genuine Holset parts HE341Ve Service Manual Table of Contents Table of Contents 1 Introduction About the Manual A TETUER 1 1 How to Use the Manual 1 1 How to Order Holset Original Parts 1 1 Description and Operation of Turbocharger 1 2 General Information 1 2 Introduction to Variable Geometry Turbochargers
21. Where key on calibration or On Engine Actuation Checks have indicated an actuation fault confirmatory electromechanical checks are recommended Ensure electrical integrity of actuator motor wiring and connectors Disconnect the DC motor at its electrical connector Using a multi meter check the resistance between connector pins 1 and 2 is 0 25 1 25 ohms Caution A To avoid feedback error to ECM always disconnect motor before position sensor Reconnect position sensor before motor If resistance is outside range replace actuator by refering to Actuator Replacement M6 x 1 0 8 mm If resistance is within range remove 4 bolt actuator coverplate and gasket to expose actuator rod end Warning Always wear safety glasses Note Where it is not possible to remove actuator coverplate on engine remove turbocharger from engine in accordance with engine service manual Component Testing and Replacement Tuba A Actuator Control Signal Engine Speed Throttle Demand ld Engine Control Module ECM Contains pre set data on airflow requirements for any fuel quantity injected at any engine speed with built in safety features for excessive boost smoke or turbocharger speed Exhaust Outlet Pressure Turbocharger Speed Actuator Position 4 12
22. alfunction continues to affect engine operation ECM will fully open VG nozzle to enable limp home facility Position sensor voltage span outside range Refer to ECM diagnostics for possible fault code data To avoid feedback error to ECM e e e 0 0 always disconnect and reconnect actuator motor and position sensor in correct sequence Disconnect motor before position sensor Reconnect position sensor before motor Check sensor wiring for bad connections Check sensor pin resistance with multimeter Repair pin or wire damage by renewing connectors and leads Remove 4 bolt actuator coverplate to expose actuator rod end Ensure stroke of assembled actuator is within range specified by service manual If in range check position sensor and ECM If outside range remove actuator Using light to medium load and locking pliers check linear travel of cross shaft pin is within same range specified for assembled actuator If pin motion is not in range replace turbocharger If pin motion is in range recheck stroke of actuator rod If less than specified by service manual replace actuator If turbocharger stroke and actuator stroke are both in range then check ECM Where position sensor malfunction continues to affect engine operation ECM will fully open VG nozzle to enable limp home acility 3 2 HE341Ve Service Manual Troubleshooting and Diagnosis Fault Finding Chart variable Geometry Engine will not S
23. all conditions of driving the turbine is electronically controlled to change the amount of air supplied to the engine to ensure maximum performance lowest fuel consumption and minimum exhaust emission levels When rapid vehicle acceleration is required the turbocharger will produce air for the engine more quickly than a conventional unit thus eliminating turbocharger lag and giving improved vehicle drivability As the engine and turbocharger run in and eventually start to wear the combination of the variable turbine and its associated electronic control will change its characteristic to keep to the original performance and emission levels over a wide range of ambient temperatures and altitude The importance of correctly installing a Variable Geometry turbocharger The bearing housing of your turbocharger and the variable geometry actuator both contain an internal liquid cooled jacket The purpose of these is to reduce the operating temperature of the housings to improve the operating environment of the position sensor and DC motor and reduce the high soak temperatures produced when the engine is switched off after being heavily loaded The addition of liquid cooling has meant that there are two pairs of pipe connections to the turbocharger to bring coolant to the housings and to take it away It is important to observe the correct installation of these pipes so that the circulation of the coolant is in the correct direction or the effectivenes
24. and reconnect actuator motor and position sensor in correct sequence Disconnect motor before position sensor Reconnect position sensor before motor Check actuator wiring for bad connections Check motor and sensor pin resistances with multimeter Repair pin or wire damage by renewing connectors and leads If no damage remove 4 bolt actuator coverplate to expose actuator rod end Apply key on calibration to activate VG actuation sequence If actuator rod travel is within range specified by service manual replace position sensor If still no rod movement remove actuator assembly and reapply key on calibration using equipment electrical Supp If rod does not move or if endplay exceeds range specified by service manual under light load replace actuator If rod moves normally through specified travel check ECM and locking pliers mole or vice grips ensure check cross shaft lever moves under light to medium force If cross shaft offers excessive or no resistance to movement replace turbocharger If cross shaft motion is acceptable and rod of reassembled actuator does not move recheck ECM Note Normal motor operation is almost silent hence a check of actuator rod movement is ee e ee required to confirm lack of motor activity DC motor not driving Refer to ECM diagnostics for possible fault code data To avoid feedback error to ECM always disconnect and reconnect actuator motor and position sensor in correct sequence Disconnect motor before
25. ant inlet and outlet adapters Torque tighten adapters to value specified by engine ep manufacturerer Where actuator threads are damaged replace actuator IN SA by reference to VG Actuator Replacement Caution A Ensure new actuator coolant adapters are fitted with o ring and washer prior to insertion Air Leakage M6 x 1 0 8 mm Caution A Visual and audible checks for air leaks may be completed safely with a running engine 2 DD Check for air leaks from the speed sensor Where leakage occurs replace o ring and torque tighten new cap head screw to value specified in Service Data Sheet Speed sensor service kit 124 is available Caution A Always use new cap head screw Ensure thread in compressor housing is clean and oil free before torque tightening Visual Checks Caution A Do not remove turbine housing as this may damage variable geometry control mechanism gt 0 ep Make visual check for damaged or bent blades Replace turbocharger if damaged or bent Caution A Never attempt to straighten blades Caution A Do not remove compressor cover as this may damage variable geometry control mechanism OPS Make visual check for damaged and fouling of impeller blades Replace turbocharger if damaged or bent Caution A Never attempt to straighten blades 4 4 HE341Ve Service Manual With intake system d
26. cation always refer to the engine diagnostic system and the fault finding chart of this manual to make all the recommended health checks It is important that intake and exhaust systems are fitted in accordance with the recommendations of the Equipment and Engine manufacturers Limiting mass inertia loading is critical to turbocharger whole life operation Maximum engine vibration input must not exceed 10g The air filter must remove particles greater than 5um at an efficiency of 95 and be of sufficient capacity to match the air consumption of the engine Recommended filters should always be used with a pressure drop indicator Intake systems must be capable of withstanding depressions up to 6 9 kPa 1 0 Ibf in Hose and clip connections of intake manifold systems must be capable of withstanding the turbocharger pressure ratio V band clamps are preferred and must be used above 3 1 pressure ratio Exhaust systems must be capable of operating at exhaust back pressures of up to 10 kPa 1 5 Ibf in This limit is increased to 13 4 kPa 2 0 Ibf in if a catalytic converter is fitted Exhaust brake applications are permitted to impose 450 kPa 65 3 Ibf in back pressure Oil should be filtered to 101m with efficiency of 60 TWA Time Weighted Average 20 um with efficiency of 8596 TWA Efficiency assessed using ISO Standard 4572 SAE J 1858 The oil quality must be as specified by the engine manufacturer and will be a minimum API SE CD MIL L
27. crankcase breather ee Refer to engine manufacturer s manual clear restriction Turbocharger bearing housing sludged or coked Change engine oil and oil filter overhaul or replace turbocharger as required Fuel injection pump or fuel injectors incorrectly set eo Refer to engine manufacturer s manual and replace or adjust faulty components as required Engine valve timing incorrect Refer to engine manufacturer s manual for correct settings and adjust as required Worn engine piston rings or liners y E Refer to engine manufacturer s manual and repair as required Burnt valves and or pistons i Refer to engine manutacturer s manual and repair as required Excessive dirt build up on compressor wheel and or diffuser vanes Clean in accordance with details in the appropriate Holset publication Turbocharger damaged _ Find and correct cause of failure repair or replace turbocharger as necessary 3 1 HE341Ve Service Manual Troubleshooting and Diagnosis Fault Finding Chart variable Geometry Engine Lacks Power Intermittent Engine Braking Intermittent Low Power Engine does not run Smoothly Low Power at Low Engine Speed t 8 4 2 so E o S D W Engine Overheats Turbocharger Noisy Poor Acceleration Reduced Braking Coolant Leak Oil Leak Actuator rod not moving Refer to ECM diagnostics for possible fault code data To avoid feedback error to ECM always disconnect
28. ead screws to the value shown in the Service Data Sheet Component Testing and Replacement 0 H PROOD 08 gt A gt b gt Ep VA g 7 Q D HE341Ve Service Manual Ensure rotor assembly freely rotates prior to engine mounting Caution A Ensure dataplate label is transferred from old to new actuator to maintain record of essential turbocharger information Component Testing and Replacement 0 H A 4 18 HE341Ve Service Manual Speed Sensor Check and Removal Where the ECM signals a speed signal error check the connection to the engine wiring harness is good If error A persists change speed sensor Caution A amp The speed sensor connector contains electronic lt gt 7 a NT components Multimeter or other electrical tests can damage the sensor Where road spray dirt and fluid ingress has caused fouling or corrosion of the speed sensor fastener apply A a penetrating oil in accordance with the manufacturer s instructions Warning A Always wear safety glasses during disassembly y M6 x 1 0 8 mm Using the socket wrench and ratchet loosen and remove the cap head screw speed sensor Caution A A Breaking the sealed fastener joint may require SUS significant torque It is essential that the socket spanner is properly engaged on the fastener to avoid Oe inadvertent damage t
29. ent Testing and Replacement 0 H 4 20 HOLSET TURBOCHARGERS Cummins Turbo Technologies Ltd Aftermarket Division Croset Avenue Huddersfield West Yorkshire HD1 6SE www holsetaftermarket com VGT Command Valve and Super MWE are trade marks of Cummins Turbo Technologies Ltd Holset and the Holset Logo are registered trade marks of Cummins Turbo Technologies Ltd Cummins and the Cummins logo are registered trade marks of Cummins Inc Part No 4029631 Rev 01 Ref JV KD Effect date 01 03 Technologies Copyright 2007 Cummins Turbo Technologies Ltd All rights reserved S Turbo
30. icates an INSTALLATION or ASSEMBLY step INSPECTION is required CLEAN the part or assembly PERFORM a mechanical or time MEASUREMENT LUBRICATE the part or assembly Indicates that a WRENCH or TOOL SIZE will be given TIGHTEN to a specific torque Ensure that the BALANCE MARKS on the rotor assembly are in alignment PERFORM an electrical MEASUREMENT Refer to another location in this manual or another publication for additional information Please wear protective clothing at all times Indicates components may be heavy Website access to find your nearest Holset Agent Go to contents 1 8 HE341Ve Service Manual Introduction Simbolos Espa ol Los simbolos siguientes son usados en estes manual para clarificar el proceso de las instrucciones Cuado aparece uno de estos simbolos su significado se espcifica en la parte inferior A Ri eb RY S m amp ADVERTENCIA Procedimientos de Mantenimiento o Servicio que al no seguirse resultar n en da os personales o p rdida de vida ATENCION Procedimientos de Mantenimiento o Servicio que al no seguirse al pie de la letra resultar n en el da o o la destrucci n del turbosobrealimentador Indica un paso de REMOCION o DESMONTAJE Indica un paso de INSTALACION o MONTAJE Se requiere INSPECCION LIMPIESE la pieza o el montaje Ejecutese una MEDICION mec nica o del tiempo LUBRIQUESE la pieza o el montaje Indica que se dar una LLAVE DE TUERCAS
31. isconnected from compressor housing it may be possible to check for excess bearing axial and radial clearances If light finger pressure causes contact between compressor or turbine wheel and respective housing replace turbocharger If in doubt the turbocharger must be removed from engine to check bearing clearance against recommended values shown in Service Data Sheet Replace turbocharger where service limits are exceeded On Engine Actuation Checks Note Always refer to ECM diagnostics for possible actuation fault data The Engine Control Module ECM features a key on calibration check to monitor the health of the VG actuation system It will potentially detect faults in Position sensing e VG actuation Speed sensing It may be possible to verify a key on calibration error using on engine visual checks Check speed sensor position sensor and actuator wiring and connectors for damage and bad connections Remake connections and if fault persists repair wiring by replacement Caution A To avoid feedback error to ECM always disconnect motor before position sensor Reconnect position sensor before motor e ep Warning Always wear safety glasses M6 x 1 0 8 mm Where it is not possible to remove 4 bolt actuator coverplate on engine due to space claim constraints it might be possible to hear actuator movement e i gt Apply key on calibration to activate VG actuation sequence As actuator moto
32. kPa 20 Ibf in must show at the oil inlet within 3 4 seconds of engine firing to prevent damage to turbocharger bearing system A flexible supply pipe is recommended The minimum oil pressure when the engine is on load must be 210 kPa 30 Ibf in Normal maximum operating pressure is 500 kPa 72 Ibf in although 600 kPa 88 Ibf in is permitted during cold start up Under idling conditions pressure should not fall below 70 kPa 10 Ibf in Recommended oil flows for the turbochargers are 2 litre min at idle and 3 litre min above maximum torque speed Ensure recommended coolant flows for the separate turbocharger and actuator circuits are achieved Turbocharger 3 litre min at idle and 5 litre min above max torque speed Actuator 1 litre min at idle and 3 litre min above max torque speed Do not use liquid gasket substances or thread sealant as any excess can enter the turbocharger oil and coolant systems to obstruct flow Note 100 kPa 1 bar 14 5037 Ibf in 2psi 1 5 HE341Ve Service Manual Introduction Installation Checklist 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Always understand why the original turbocharger needs replacing before fitting another unit Check the turbocharger dataplate to ensure the Part No is correct for the engine application Check the engine exhaust intake and aftercooler systems are clean and without obstruction i e free from oil gasket pieces dust di
33. no fault found Before assuming the turbocharger is not performing to specification always refer to the engine diagnostic system and the troubleshooting diagnostic procedures of this manual Warning Turbocharger surface temperature during operation can achieve 700 C 1300 F The designated turbocharger weighs up to 18 3 kg 40 5 Ib and is fitted with external parts that are sensitive to manual handling They include electrical wiring and connectors Caution A Orientation of the turbine housing of a variable geometry turbocharger is factory set Any attempt to re orientate the housing can cause severe damage to the VG mechanism and may void warranty Caution A This variable geometry turbocharger has been factory balanced using the core balance process Service overhaul repair must be carried out by Holset Engineering to ensure the variable geometry system is correctly rebuilt It is important to note that operating a turbocharger with rotor or core balance level greater than design limits could cause turbocharger or engine failure Warning Some parts are manufactured in fluoroelastomers eg Viton or similar that require special treatment in the case of repair and service after fire 1 4 HE341Ve Service Manual Introduction Installation Data 1 11 12 13 14 15 16 Holset Service receives many turbocharger returns that are no fault found Before assuming the turbocharger is not performing to specifi
34. not recommended to use the original fasteners when re fitting an original or new actuator Caution A Where an original fastener must be used it is important that the threads are clean and thread locking compound is applied to achieve a vibration proof connection Fastener torque must be applied within the time allowed by the sealant manufacturers Warning A Always wear safety glasses Assemble three fasteners loosely in sequence A Gp bd OJAD e VA SD gt 5 3 Q VA SD SS Component Testing and Replacement 0 H 4 16 HE341Ve Service Manual Use a calibrated torque wrench to tighten three screws in sequence to value specified in Service Data Sheet Warning A Always wear safety glasses Caution A The torquing sequence is important to prevent road spray ingress At this stage prior to fitting coverplate It is possible to verify correct actuator movement Apply system voltage to actuator motor through on off switch Check rod end travel is within range shown in Service Data Sheet Caution A To avoid feedback error to ECM always disconnect Motor before position sensor Reconnect position sensor before motor M6 X 1 0 8 mm Sub assemble 4 bolt coverplate and gasket using the push fit of the cap head screws in the gasket Using a calibrated torque wrench torque tighten the 4 cap h
35. ntinue to operate to Holset Service standard on completion of overhaul Manual sections 1 to 5 where applicable appear as a self extracting compressed file which is organised according to the steps needed to most easily and correctly maintain the operation of the turbocharger Users are required to download this file to hard disk Section 6 has its own file identity and resides at www holset co uk so that Holset can update the Service Data as changes occur The links between manual and service data are active only when the user is connected to the Internet Chapter 6 has an expiry date to encourage users to discard outdated saved or printed versions and always access the latest information available at www holset co uk When using the manual on line this icon will link to Holset s website to help find your nearest agent for advice and how to order Holset original parts How to Order Holset Original Parts To make sure of optimum performance certain items must be discarded during disassembly and replaced with new for re assembly These items are indicated in the Service and Overhaul section with the use of a symbol All items showing a are available in a basic overhaul kit To get the correct parts for your turbocharger refer to the component identification section of this manual to help you find the following information 1 Refer to the exploded view and component list to define the major components to be replaced 2 Refer to the
36. o el TAMA O DE HERRAMIENTA APRIETESE hasta un par torsor especifico Ceri rese de que est n alineadas las marcas de balance en el rotor EJECUTESE una MEDICION el ctrica Para informaci n adicional refi rase a otro emplazamiento de este manual o a otra publicaci n anterior Favor de siempre llevar ropa protectora Indica que los componentes pueden ser pesados Acceso a Sitio Web para localizar su agente Holset m s cercano Ir a la tabla de materias 1 9 HE341Ve Service Manual Introduction Symboles Francais Les symboles suivants sont utilis s dans ce manuel pour aider communiquer le but des instructions Quand l un de ces symboles apparait il voque le sens d fini ci dessous A QS eb E m amp ATTENTION DANGER Proc dures de maintenance ou d entretien qui si elles ne pas observ es correctement auront pour r sultat des l sions corporelles ou un d c s MISE EN GARDE Proc dures de maintenance ou d entretien qui si elles ne sont pas observ es strictement auront pour r sultat de causer des d g ts au turbocompresseur ou de conduire sa destruction Indique une op ration de DEPOSE Indique une op ration de MONTAGE L INSPECTION est n cessaire NETTOYER la pi ce ou l ensemble EFFECTUER une MESURE m canique ou de temps GRAISSER la pi ce ou l ensemble Indique qu une DIMENSION DE CLE ou D OUTIL sera donn e SERRER un couple sp cifique S assurer que
37. o speed sensor cable and connector resulting from a spanner slip KC Extract the speed sensor ensuring that the o ring seal 7 Z is removed with the sensor This is conveniently SUS achieved by tilting the sensor as it exits its recessed bore Ge Place the speed sensor on a clean surface to avoid collection of unwanted ferrous particles Component Testing and Replacement 0 H 4 19 HE341Ve Service Manual Speed Sensor Replacement Speed sensor kits 124 are available Warning A Always wear safety glasses during disassembly Prior to inserting speed sensor ensure it is clean and unable to collect magnetic particles as it is inserted Ensure the o ring seal is in position on the sensor body The o ring moves automatically into its fitted position during insertion M6 x 1 0 8 mm Use new cap head screw with patch sealant feature provided in service kit 124 to fasten speed sensor flange to bearing housing Torque tighten to the value specified in Service Data Sheet Caution A It is not recommended to use the original fastener when re fitting an original or new speed sensor Caution A Where an original fastener must be used it is important that the threads are clean and thread locking compound is applied to achieve a vibration proof connection Fastener torque must be applied within the time allowed by the sealant manufacture A Compon
38. ocharger Noisy Oil Leak from Turbine Seal Dirty air cleaner Clean or replace element according to manufacturer s recommendations Restricted compressor intake duct Remove restriction or replace damaged parts as required Restricted air duct from compressor to intake manifold Remove restriction or replace damaged parts as required Restricted intake manifold em Refer to engine manufacturer s manual and remove restriction Air leak in feed from air cleaner to compressor Replace seals gaskets or tighten fasteners as required Air leak in feed from compressor to intake manifold Replace seals gaskets or tighten fasteners as required Air leak between intake manifold and engine Refer to engine manufacturer s manual and replace gaskets or tighten fasteners as required Foreign object in exhaust manifold from engine Refer to engine manufacturer s manual and remove obstruction Restricted exhaust system i e Remove restriction or replace damaged parts as required Exhaust manifold cracked gaskets blown or missing Refer to engine manufacturer s manual and replace gaskets or damaged parts as required Gas leak at turbine inlet exhaust manifold joint e o Replace gasket or tighten fasteners as required Gas leak in ducting after turbine outlet y e e Refer to engine manufacturer s manual and repair leak Restricted turbocharger oil drain line Remove restriction or replace damaged parts as required ee 0 0 Restricted engine
39. position sensor Reconnect position sensor before motor Check sensor wiring for bad connections Check sensor pin resistance with multimeter Repair pin or wire damage by renewing connectors and leads Remove 4 bolt actuator coverplate to expose actuator rod end Check cross shaft is not fouling on actuator body screws Remove actuator and apply light axial load to rod to check endplay If greater than specified in service manual replace actuator Refer to position sensor voltage span outside range for further fault finding Where position sensor malfunction continues to affect engine operation ECM will fully open VG nozzle to enable limp home facility Position sensor nozzle closed voltage outside range Refer to ECM diagnostics for possible fault code data To avoid feedback error to ECM e oo e always disconnect and reconnect actuator motor and position sensor in correct sequence Disconnect motor before position sensor Reconnect position sensor before motor Check sensor wiring for bad connections Check sensor pin resistance with multimeter Repair pin or wire damage by renewing connectors and leads Remove 4 bolt actuator coverplate to expose actuator rod end Check cross shaft is not fouling on actuator body screws Remove actuator and apply light axial load to rod to check endplay If greater than specified in service manual replace actuator Refer to position sensor voltage span outside range for further fault finding Where position sensor m
40. r operates correctly with low electrical hum no noise does not necessarily imply no actuation However high noise may indicate an actuator problem In this case refer to Actuator Check and Removal and Actuator Replacement Component Testing and Replacement Fuel Injection Pump I Ambient Pressure and Temperature d Engine Control Module ECM Contains pre set data on airflow requirements for any fuel quantity injected at any engine speed with built in safety features for excessive boost smoke or turbocharger speed Exhaust Outlet Pressure ja ia Lee Turbocharger Speed Actuator Position CA eS A ATS 10 N p 20 HE341Ve Service Manual Warning A Key on calibration sequence automatically extends retracts actuator over its full travel Keep fingers away from rod Apply key on calibration sequence to actuator motor and use steel rule to measure travel If VG mechanism travel is within permissible range shown in Service Data Sheet there may be a position sensor fault In this case refer to Position Sensor Check and Removal If VG mechanism does not move or if travel is outside permissible range shown in Service Data Sheet remove actuator by reference to Actuator Check and Removal If on engine actuator removal is possible use equipment
41. rt carbon or foreign objects Replace the oil and air filters using replacement parts specified by the equipment manufacturer Change the engine oil using the type specified by the engine manufacturer Check that the turbocharger oil inlet and drain pipes and connectors are clean free from obstruction and will not leak under pressure Before re installing flexible pipes always ensure any burnt on lacquer or other adhered material is removed from internal bores If in doubt always fit new pipes Check that the coolant pipes of water cooled bearing housing applications and connectors are clean free from obstruction and will not leak under pressure To pre lube the turbocharger bearings pour some clean engine oil into the oil inlet and rotate the turbocharger rotor assembly by hand Check that the exhaust manifold flange is flat and undamaged Mount the turbocharger on the flange and check that the turbine inlet gasket fits properly without obstructing the gas passages Torque fasteners to engine manufacturer s recommendation Assemble the air intake and boost outlet connections Check that the connections are secure and will not leak in use Check the exhaust system is fitted using the original mounting arrangement provided by the equipment manufacturer Always re fit any supports brackets back in position to ensure the system is correctly supported Assemble the exhaust system to the turbine housing outlet Check that the gasket connection
42. s of the cooling system will be lost and severe damage may result 1 2 HE341Ve Service Manual Introduction The advantages of a Variable Geometry VG Turbocharging system You may already have experience of the effect of a Wastegate turbocharger on the performance of your vehicle The advantage of Variable Geometry over a Wastegate system is that all the exhaust gas flows through the turbine wheel to increase net turbine power output In addition turbine power can be set to provide just sufficient energy to drive the compressor at the desired boost level wherever the engine is operating Speed actuator position and pressure sensors feedback information to the Engine Control Module to provide the necessary control As the name suggests a Wastegate turbocharger allows exhaust gas to by pass the turbine wheel This by passed gas contains energy which is lost to the turbine wheel Wastegate turbochargers have no feedback controls Boost Air Outlet Air Inlet Sliding Nozzle Ring and Blades Extended The Holset VG system works by controlling the width of a nozzle guiding the gas flow into the turbine wheel Control is achieved using an electric actuator powered by the vehicle system The Engine Control Module continually senses the position of the actuator mechanism engine operating condition and driver demands It signals the actuator DC motor to move the actuator rod to a new position which slides the nozzle ring and blades relative
43. sing 1 153 Position Sensor 1 106 Screw Socket Head 2 105 Connector Male Water 2 123 VG Bearing Housing Seals and Adapter Kit Water amp Oil comprising 1 053 Gasket Oil Outlet 1 113 Adapter Oil Inlet 1 114 O Ring Seal Oil Inlet 1 105 Connector Male Water 2 115 O Ring Seal Water 2 124 Speed Sensor Kit comprising 1 112 Speed Sensor 1 120 Screw Cap Head 1 27 O Ring Seal 1 Note Exploded views may not contain all listed components 2 4 HE341Ve Service Manual Component Identif cation Purchasable Service Tools H Service Tools The following special tools can be purchased from your local Authorised Repair Location The use of these tools is recommended and where necessary they are shown in the appropriate service procedure Part No Tool Description Tool Illustration 3575186 Circlip Pliers 4027202 Wastegate Air Feed Adapter 4027203 Wastegate Air Feed Adapter 4027204 E Clip Tool Caution A All Service and Maintenance settings are shown in Holset s Service Data Sheet It is essential that these settings are used Common tools found in mechanic s tool box not included 2 5 HE341Ve Service Manual Troubleshooting and Diagnosis Fault Finding Chart an Applications Cyclic Sound from the Turbocharger Oil Leak from Compressor Seal o 0 a D o A a a FE la o a Engine Running Hot Engine Lacks Power Black Exhaust Smoke Blue Exhaust Smoke High Oil Consumption Turb
44. socket head screws are provided in position sensor service kit 152 These have patch sealant feature and must be fitted dry Torque tighten to value shown in Service Data Sheet Caution A It is not recommended to use the original fasteners when re fitting an original or new position sensor Caution A Where an original fastener must be used it is important that the threads are clean and thread locking compound is applied to achieve a vibration proof connection Fastener torque must be applied within the time allowed by the sealant manufacturer Caution A To avoid feedback error to ECM always disconnect motor before position sensor Reconnect position sensor before motor 4 11 HE341Ve Service Manual Actuator Check and Removal Caution A Actuator checks should be carried out on engine If actuator or turbocharger removal is necessary engine systems are disrupted Water system drained Position sensor disconnected Speed sensor disconnected Oil circuit disassembled Caution A Never remove actuator mechanism 5 bolt cover plate as this will adversely effect actuator clearance conditions Note Always refer to ECM diagnostics for possible actuation fault data The Engine Control Module ECM features a key on calibration check of the VG actuation system When combined with electro mechanical checks it will potentially detect faults in e VG mechanism e VG actuator Position sensor
45. t block rotates freely remove pivot block and check linear travel of VG cross shaft pin is within permissible range shown in Service Data Sheet If pin shows no resistance to motion does not travel within permissible range replace turbocharger Caution A Use moderate hand force only to rotate cross shaft If pin travel within range check pivot block bore and crankpin diameter If pivot block bore is greater than 6 04 mm 0 238 in replace pivot block If crankpin diameter is less than 5 99 mm 0 236 in replace turbocharger Se Component Testing and Replacement 0 H 10 20 30 40 50 60 70 80 9 Abbado bd 4 14 HE341Ve Service Manual Remote Actuator Check gt Note Always refer to ECM diagnostics for possible Ser actuation fault data SJ Disconnect electrical supply Check actuator rod backlash is less than the value shown in the Service Data Sheet Caution A To avoid feedback error to ECM always disconnect motor before position sensor Reconnect position sensor before motor gt 00 Apply system voltage to actuator motor Use a steel rule to check actuator travel is within Sen permissible range shown in Service Data Sheet NS Caution A Detached actuator stroke is greater than stroke when attached to VG cross shaft Ensure correct range is read from Service Data Sheet Component Testing and Replacement LO e
46. tart Engine Lacks Power Engine Overheats Intermittent Engine Braking Intermittent Low Power Engine does not run Smoothly Low Power at Low Engine Speed Turbocharger Noisy Poor Acceleration Reduced Braking Coolant Leak Oil Leak Variable geometry nozzle movement slow or inconsistent Refer to ECM diagnostics for possible fault code data To avoid feedback error to ECM always disconnect and reconnect actuator motor and position sensor in correct sequence Disconnect motor before position sensor Reconnect position sensor before motor Check actuator wiring for bad connections Repair pin or wire damage by renewing connectors and leads If no damage remove 4 bolt actuator coverplate to expose actuator rod end Apply separate voltage to motor using service test equipment Fully retract rod end using voltage toggle switch Drive actuator through full cycle using toggle switch and measure cycle time f time is within specification replace position sensor If nozzle movement remains slow or inconsistent remove actuator assembly and locking pliers ensure cross shaft lever moves under light to medium force If cross shaft offers excessive resistance to movement replace turbocharger If cross shaft motion is acceptable reapply separate voltage to motor If rod shows signs of stiction replace actuator If rod of new assembled actuator still suspect recheck ECM Where position sensor malfunction continues to affect engine operation ECM will f
47. turbocharger s dataplate which will be found on the compressor housing or actuator to define the identifying information about your turbocharger build standard 3 Contact your local Holset agent with componant identification nos and dataplate assembly no serial no and turbocharger type 4 With this information your local agent can provide you with the optimum kit of parts for re assembling your turbocharger for continued long life operation 1 1 HE341Ve Service Manual Introduction Description and Operation of Turbocharger General Information A turbocharger is a mechanical device which uses the engine s exhaust gases to force more air into the engine cylinders Hot exhaust gas energy is used to turn a turbine wheel and shaft At the other end of the shaft is the compressor impeller or compressor wheel which draws in air and forces it into the engine cylinders Supplying increased air mass flow to the engine provides improved engine performance lower exhaust smoke density improved operating economy and altitude compensation The turbocharger has proven to be one of the most beneficial devices for improving engine performance It performs its job very well as long as it is properly cared for Introduction to Variable Geometry Turbochargers The need for Variable Geometry The turbocharger on your vehicle s engine is of a very advanced type which varies the effective size of its turbine in response to the driver s demands Under
48. ully open VG nozzle to enable limp home facility VG mechanism intermittent jammin Refer to ECM diagnostics for possible fault code data To avoid feedback error to ECM always disconnect and reconnect actuator motor and position sensor in correct sequence Disconnect motor before position sensor Reconnect position sensor before motor Check actuator wiring for bad connections Repair pin or wire damage by renewing connectors and leads If no damage remove 4 bolt actuator coverplate to expose actuator rod end Apply separate voltage to motor using service test equipment If actuator travels within range specified by service manual fully retract rod end using voltage toggle Switch Drive actuator through full cycle using toggle switch and measure cycle time If time is within specification replace position sensor If actuator movement remains slow or inconsistent remove actuator assembly and using locking pliers ensure cross shaft lever moves under light to medium force If cross shaft offers excessive resistance to movement replace turbocharger If cross shaft motion is acceptable reapply separate voltage to motor of replacement actuator using senice tool If rod of new assembled actuator still slow or inconsistent then recheck ECM Where position sensor malfunction continues to affect engine operation ECM will fully open VG nozzle to enable limp home facility Pivot block seized on cross shaft pin Refer to ECM
49. urbocharger from engine Note Always refer to ECM diagnostics for possible actuation fault data Where key on calibration or On Engine Actuation Checks have indicated a position sensor fault final confirmatory checks are recommended Ensure electrical integrity of sensor wiring and connectors Caution A To avoid feedback error to ECM always disconnect motor before position sensor Reconnect position sensor before motor Disconnect the sensor at its electrical connector Using a multi meter check the resistance between connector pins 1 and 3 is 800 1200 ohms with the sensor at 20 C Apply key on calibration check and measure voltage from position sensor pin 1 to pin 3 is in the range 1 to 5 volts dc M6 x 1 0 8 mm Remove 4 bolt actuator coverplate and gasket to expose actuator rod end Warning Key on calibration sequence automatically extends retracts actuator over its full travel Keep fingers away from rod Warning Always wear safety glasses Component Testing and Replacement amp gt hom ms Id A Bg ct Actuator Control Signal Engine Speed Engine Control Module ECM Exhaust Outlet Pressure Throttle Demand EL Contains pre set data on id airflow requirements for any fuel quantity injected at any engine speed with built in safety features for excessive boost smoke or turbocharger speed
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