NOTE: It is normal for a small amount of gases from the combustion chamber to enter the crankcase. This gas is blown into the air intake system thanks to the forced crankcase ventilation system (PCV), which has a built-in oil separator. Together with the gases blown out of the crankcase, a certain amount of engine oil in the form of steam enters the air intake system (this engine oil also contributes to extending valve seat life). This means that oil will collect inside the air intake and turbocharger elements. This is not an indication of a defective turbocharger oil seal. The turbocharger oil seal will not fail until the bearings fail first, causing the turbocharger compressor to make noise and seize. A new turbocharger should not be installed due to oil penetration into the turbocharger or air intake system components. If a leak is detected in the supply and return oil lines or their connections, find and eliminate the cause. A new turbocharger should not be installed due to oil leakage.
1. Check the customer's complaint.
2. Perform a visual check for obvious signs of mechanical damage.
Visual Inspection Table
|
Mechanical factors |
Electrical Factors |
|
leak (And) oils |
Wiring harness |
|
Air filter element |
electrical connector (s) |
|
Air filter outlet pipe |
Vane Adjustment Solenoid Valve - 115 HP Diesel Vehicles |
|
Air filter inlet pipe |
RSM |
|
Turbocharger supply or return oil lines |
|
|
Turbine Bypass Control Valve - 75 HP Diesel Vehicles or 90 hp |
|
|
Vacuum Diaphragm Unit - 115 HP Diesel Vehicles |
|
|
turbocharger housing |
3. If an obvious cause of the problem you identified or described by the client is found, eliminate this cause before proceeding to further actions (if possible).
4. If the cause is not visually obvious, check the symptom and refer to the Symptom Chart.
Symptom table
NOTE: The vacuum diaphragm assembly is an integral part of the turbocharger and cannot be separately replaced or adjusted.
|
State |
Possible Causes |
Action |
|
• Blue smoke accompanied by excessive turbocharger noise |
• The turbocharger's compressor is rubbing against the body walls. •Turbine of the turbocharger touches the walls of the housing. • Bearings and oil seal (I) turbocharger. • Turbocharger oil supply line blocked or damaged. |
• Go to PINPOINT TEST A. |
|
• Blue smoke without increased turbocharger noise |
•Clogged or damaged turbocharger oil return line. |
• Go to PINPOINT TEST B. |
|
• Poor engine performance - vehicles with a 75 hp diesel engine. or 90 hp |
• Vacuum line (And) turbine bypass control valve. |
•CHECK if all vacuum lines are installed and if there are signs of air leaks. Make any necessary repairs. |
|
• Unauthorized adjustment of the turbine bypass control valve drive stem. |
• Turbocharger boost pressure is set at the factory and cannot be adjusted. CHECK for a broken paint seal on the vacuum diaphragm unit drive rod. If the seal is broken, INSTALL a new turbocharger. For more information, refer to Turbocharger - 75 HP Diesel Vehicles. or 90 hp available in this section. |
|
|
• Actuator rod for turbine bypass control valve. |
•CHECK the turbine bypass control valve actuator for freedom of movement. If the turbine bypass control valve actuator does not move freely. CHECK for signs of damage or signs of foreign material. Make any necessary repairs. • Go to PINPOINT TEST C. |
|
|
• Poor engine performance - vehicles with a 115 hp diesel engine. |
• Vacuum lines of the vacuum diaphragm block. |
•CHECK if all vacuum lines are installed and if there are signs of air leaks. Make any necessary repairs. |
|
• Unauthorized adjustment of the drive rod of the vacuum diaphragm unit. |
• Turbocharger boost pressure is set at the factory and cannot be adjusted. CHECK for a broken paint seal on the vacuum diaphragm unit drive rod. If the seal is broken, INSTALL a new turbocharger. For more information, refer to Turbocharger - 115 HP Diesel Vehicles. available in this section. |
|
|
• Driving rod of the vacuum diaphragm block. |
• CHECK the freedom of movement of the drive rod of the vacuum diaphragm unit. If the drive rod of the vacuum diaphragm unit does not move freely. CHECK for signs of damage or signs of foreign material. Make any necessary repairs. • Go to PINPOINT TEST D. |
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