Turbocharger Actuator - Installation

6.7L DIESEL










1. Clean turbocharger actuator housing (2) and turbocharger mounting surfaces.

CAUTION: The electronic turbocharger actuator (2) must be removed from the turbocharger to perform this function. Turbocharger failure could result if the electronic turbocharger actuator (2) is not removed from the turbocharger.

2. Position turbocharger actuator (2) in engine compartment so the actuator gear (1) will be free to rotate.
3. Connect turbocharger actuator electrical connector.
4. Connect negative battery cable.
5. Using a scan tool function "MISC FCN" under ECU, perform TURBO ACTUATOR PRE-ALIGN/SELF CALIBRATE.

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

CAUTION: Use only turbocharger actuator grease supplied in the service kit. Use of any other type of grease or too much grease may result in damage to turbocharger. Use the full amount of grease supplied with the service kit.

6. Apply grease to turbocharger actuator sector gear in a line across center of all teeth.
7. Install O-ring on turbocharger actuator.










8. If necessary, rotate sector gear (1) clockwise (rearward) and insert small end of alignment tool (or 0.125 in. pin or a 1/8 in drill.) through sector gear alignment hole (3) until it engages the alignment hole in turbocharger bearing housing (2) and sector gear will not rotate. If alignment pin does not engage hole in turbocharger bearing housing (2) , variable geometry mechanism is not opening completely, refer to Testing and Inspection.










9. Rotate turbocharger sector gear (1) counterclockwise (forward). Insert large end of alignment pin (or a 0.187 in. pin or a 3/16 in. drill) through sector gear alignment hole (2) until it engages 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 closing completely. Turbocharger must be replaced.

10. Install guide pins on turbocharger.
11. Remove alignment pin from turbocharger actuator sector gear. Turbocharger actuator sector gear must stay in this position, rotated fully clockwise while installing actuator.
12. Position turbocharger actuator on guide pins and install.
13. Install two mounting screws. Hand tighten only.
14. Remove guide pins. Install remaining two mounting screws. Tighten mounting screws in a cross pattern to 11 Nm (96 in. lbs.).

CAUTION: The electronic turbocharger actuator must be installed on the turbocharger before performing this step. Incomplete installation of the electronic turbocharger actuator will result in failure of the calibration procedure.

15. 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.

16. Place ignition in the OFF position.
17. Install air filter housing Air Cleaner Body - Installation.
18. Fill cooling system Service and Repair.