Installation

INSTALLATION




1. Clean turbocharger actuator housing and turbocharger mounting surfaces.
2. Position turbocharger actuator in engine compartment so gear will be free to rotate.
3. Connect turbocharger actuator electrical connector.
4. Connect negative battery cable.
5. Using a scan tool, perform TURBO ACTUATOR PRE-ALIGN.

NOTE: Do not turn key OFF after performing TURBO ACTUATOR PRE-ALIGN procedure. This holds the actuator gear in position for installation.

CAUTION: Use only turbocharger actuator grease. Use of any other type of grease or too much grease may result in damage to turbocharger.

6. Apply grease to turbocharger actuator sector gear in a line across center of all teeth.
7. Install O-ring on turbocharger actuator.
8. Install guide pins on turbocharger.
9. Rotate turbocharger sector gear clockwise and insert small end of turbocharger actuator alignment tool (supplied with new actuator) or 3.175 mm (1/8 in.) drill, through sector gear until it engages the alignment hole in turbocharger bearing housing and sector gear will not rotate. If alignment pin does not engage hole in turbocharger bearing housing, variable geometry mechanism is not opening completely.
10. Remove pin from turbocharger actuator sector gear. Turbocharger actuator sector gear must stay in this position, rotated fully clockwise while installing actuator.
11. Position turbocharger actuator on guide pins and install.
12. Install two mounting screws. Hand tighten only.
13. Remove guide pins. Install remaining two mounting screws. Tighten mounting screws in a cross pattern to 11 Nm (96 in. lbs.).
14. Using scan tool, perform TURBO ACTUATOR SELF CALIBRATE procedure.

NOTE: If the TURBO ACTUATOR SELF CALIBRATE procedure fails, remove actuator and repeat installation one additional time. If this fails to clear error, replace turbocharger.

15. Place ignition in the OFF position.
16. Install air filter housing.
17. Fill cooling system.