KENR8772

59

Testing and  Adjusting Section

Before you begin inspection of the  turbocharger,

be sure that the  inlet air restriction is within the

specifications for your engine.  Be sure that the

exhaust system restriction is within the specifications

for your engine. Refer to Systems Operation, Testing

and Adjusting, “Air Inlet  and Exhaust System -

Inspect”.

3.  Turn the rotating assembly by hand. While you

turn the assembly, push the assembly sideways .

The assembly should turn freely. The compressor

wheel should not rub the compressor housing.

Replace the turbocharger if the compressor wheel

rubs the compressor wheel housing. If there is no

rubbing or scraping, go to Step 4.

The condition of the turbocharger will have definite

effects on engine performance. Use the following

inspections and procedures  to determine the

condition of the turbocharger.

4.  Inspect the compressor and the compressor

wheel housing for oil leakage. An oil  leak from

the compressor may deposit oil in the aftercooler.

Drain and clean the aftercooler if you  find oil in

the aftercooler.

•  Inspection of the Compressor and the Compressor

Housing

a.  Check the oil level in the crankcase. If the oil

level is too high, adjust the oil level.

•  Inspection of the Turbine Wheel and the Turbine

Housing

b. Inspect the air cleaner element for restriction. If

restriction is found, correct the problem.

Inspection of the Compressor and

the Compressor Housing

c.  Inspect the engine crankcase breather. Clean

the engine crankcase breather  or replace

the engine crankcase breather if the engine

crankcase breather is plugged.

d. Remove the oil drain line for the turbocharger.

Inspect the drain opening. Inspect the oil drain

line. Inspect the area between the bearings of

the rotating assembly shaft. Look for oil sludge.

Inspect the oil drain hole for oil sludge. Inspect

the oil drain line  for oil sludge in the drain

line. If necessary, clean the rotating assembly

shaft. If necessary, clean the oil drain hole. If

necessary, clean the oil drain line.

e.  If Steps 4.a through 4.d did not  reveal the

source of the oil leakage, the turbocharger has

internal damage. Replace the turbocharger.

Inspection of the Turbine Wheel

and the Turbine Housing

Remove the air piping from the turbine housing.

g02317693

Illustration 49

Typical example

(1) Compressor housing

(2) Turbine housing

Remove air piping from the compressor inlet.

1.  Inspect the compressor wheel for damage from a

foreign object. If there is damage, determine the

source of the foreign object. As required, clean

the inlet system and repair the  intake system.

Replace the turbocharger. If there is no damage,

go to Step 3.

2.  Clean the compressor wheel and  clean the

compressor housing if you find buildup of foreign

material. If there is no buildup of foreign material,

go to Step 3.

This document is printed from SPI². Not for RESALE

60

KENR8772

Testing and  Adjusting Section

b. If crankcase pressure is high, or if the oil drain

is restricted, pressure in the center housing

may be greater than the pressure of turbine

housing (1). Oil flow may be forced in the wrong

direction and the oil may not drain. Check the

crankcase pressure and correct any problems.

c.  If the oil drain line is damaged, replace the oil

drain line.

d. Check the routing of the oil drain line. Eliminate

any sharp restrictive bends. Make sure that

the oil drain line is not too close to the engine

exhaust manifold.

e.  If Steps 4.a through 4.d did not  reveal the

source of the oil leakage, turbocharger (3) has

internal damage. Replace turbocharger (3).

Check the  Wastegate for Proper

Operation

g00763164

Illustration 50

Typical example

Table 3

(1) Turbine Housing

(2) Turbine Wheel

(3) Turbocharger

Required Tools

Part

Tool

A

Number

Part Description

Qty

1.  Inspect the turbine for damage by a foreign object.

If there is damage, determine the source of the

foreign object. Replace turbocharger (3). If there

is no damage, go to Step 2.

21825617

Dial Gauge

1

2.  Inspect turbine wheel (2) for buildup of carbon and

other foreign material. Inspect turbine housing (1)

for buildup of carbon and foreign material. Clean

turbine wheel (2) and clean turbine housing (1) if

you find buildup of carbon or foreign material. If

there is no buildup of carbon or foreign material,

go to Step 3.

3.  Turn the rotating assembly by hand. While you

turn the assembly, push the assembly sideways.

The assembly should turn freely. Turbine wheel (2)

should not rub turbine wheel housing (1). Replace

turbocharger (3) if turbine wheel (2) rubs turbine

housing (1). If there is no rubbing or scraping, go

to Step 4.

4.  Inspect the turbine and turbine housing (1) for oil

leakage. Inspect the turbine and turbine housing

(1) for oil coking. Some oil coking may be cleaned.

Heavy oil coking may require  replacement of

the turbocharger. If the oil  is coming from the

turbocharger center housing go to Step 4.a.

g02317713

Illustration 51

Typical example

1.  Disconnect the pipe for the boost sensor (2) at

the wastegate actuator (3). Connect an air supply

to the wastegate actuator that can be adjusted

accurately.

a.  Remove the oil drain line for the turbocharger.

Inspect the drain opening. Inspect the  area

between the bearings of the rotating assembly

shaft. Look for oil sludge. Inspect the oil drain

hole for oil sludge. Inspect the  oil drain line

for oil sludge. If necessary, clean the rotating

assembly shaft. If necessary, clean the drain

opening. If necessary, clean the drain line.

2.  Install Tooling (A) to the turbocharger so  that

the end of the actuator rod (1) is in contact with

Tooling (A). This will measure axial movement of

the actuator rod (1).

This document is printed from SPI². Not for RESALE

KENR8772

61

Testing and  Adjusting Section

3.  Slowly apply air pressure to the wastegate so that

the actuator rod (3) moves 0.4 mm (0.016 inch).

Refer to Specifications, “Turbocharger” for the

correct pressure for the wastegate. Ensure that the

dial indicator returns to zero when the air pressure

is released. Repeat the test several times. This

will ensure that an accurate reading is obtained.

Air Under Water Leak Test Procedure.

4.  If the operation of the wastegate is not correct,

engineering to advise if the turbocharger should be

replaced or the actuator rod should be replaced.

5.  Repeat steps 1 to 4 in order to repeat the pressure

test.

6.  If the air pressure is correct, remove the air supply.

Remove Tooling (A). Install the pipe for the boost

sensor (2).

i02788813

Exhaust Temperature - Test

g02390879

Illustration 52

Typical example

Table 4

1.  Install Tooling (A) at positions (X) and (Y) to the

exhaust cooler (NRS) (1). Tighten the bolts that

secure the plates to a maximum torque of 20 N·m

(15 lb ft).

Required Tools

Tool

Part Number

Part Description

Qty

A

-

Infrared Thermometer

1

Note: A plug is required for sealing the open end of

the inlet side (2) of the exhaust cooler (NRS) (1) for

pressure testing.

When the engine runs, the temperature of an exhaust

manifold port can indicate the condition  of a fuel

injection nozzle.

2.  Connect an air supply to pressure test plate at

position (Z). Apply a pressure of 207 kPa (30 psi).

A low temperature indicates that no fuel is flowing to

the cylinder. An inoperative fuel injection nozzle or

a problem with the fuel injection pump could cause

this low temperature.

3.  While the exhaust gas cooler  (NRS) is still

pressurized, submerge the cooler in water that is

at ambient temperature.

A very high temperature can indicate that too much

fuel is flowing to  the cylinder. A malfunctioning

fuel injection nozzle could  cause this very high

temperature.

4.  Allow the exhaust gas cooler (NRS) to settle in

order for the air that is trapped to escape.

5.  Observe the exhaust gas cooler (NRS) for air

bubbles that indicate a leak. If  air bubbles are

seen within 3 minutes, this indicates a leak with

the exhaust gas cooler (NRS). Note the location

or the origin of the leak. Record this information.

Use Tooling (A) to check exhaust temperature.

i04201411

Exhaust Cooler (NRS) - Test

(If Equipped)

6.  If no bubbles are detected after 3 minutes, the

exhaust gas cooler (NRS) is reusable.

7.  Remove the exhaust gas cooler (NRS) from the

water. If the exhaust gas cooler (NRS) does not

leak, the problem may be elsewhere in the cooling

system or the engine. Refer the service manual

in order to check for leakage. If the exhaust gas

cooler (NRS) does leak, the exhaust gas cooler

(NRS) should be replaced.

Table 5

Required Tools

Tool

Part Number

Part Description

Qty

A

27610408

Pressure Test Plates

1

This document is printed from SPI². Not for RESALE

62

KENR8772

Testing and  Adjusting Section

i04935303

i04032141

Engine Crankcase Pressure

(Blowby) - Test

Engine Valve  Lash  -

Inspect/Adjust

Table 6

Required Tools

Part

Tool

Number

Part Name

Quantity

A

-

Pressure Gauge

1

Damaged pistons or rings  can cause too much

pressure in the crankcase. This condition will cause

the engine to run rough. There will be more than the

normal amount of fumes (blowby) rising  from the

crankcase breather. The breather can then become

restricted in a short time,  causing oil leakage at

gaskets and seals that would  not normally have

leakage. Blowby can also be caused by worn valve

guides or by a failed turbocharger seal.

g01284058

Illustration 53

Cylinder and valve location

(A) Inlet valve

(B) Exhaust valve

1.  Install Tooling (A) to the most convenient location

on the output tube for the crankcase breather or

the breather hose. A suitable adaptor  may be

required in addition to the pressure gauge.

If the valve lash requires adjustment several times

in a short time period, excessive wear  exists in a

different part of the engine. Find the  problem and

make necessary repairs in order to prevent  more

damage to the engine.

2.  Operate the engine at a speed of 1500 rpm or

1800 rpm with no load. Allow the gauge reading to

stabilize before taking the pressure reading.

Not enough valve lash can be  the cause of rapid

wear of the camshaft and valve lifters. Not enough

valve lash can indicate that the seats for the valves

are worn.

The engine blowby should be less  than 50 L/min

(13 US gpm) for a new engine.

The maximum engine blowby should be 200 L/min

(53 US gpm).

Valves beco, me worn due to the following causes:

•  Fuel injection nozzles that operate incorrectly

Note: Do not use the data alone to determine if the

engine should be overhauled. Other indicators such

as high oil consumption, low power, hard starting,

and excessive fuel consumption must be considered.

•  Excessive dirt and oil are present on the filters for

the inlet air.

•  Incorrect fuel settings.

After a new engine is  used for a short time, the

blowby can decrease as the rings are seated. New

engines should be checked for blowby  during all

maintenance checks. As the piston rings and cylinder

walls wear, the blowby will gradually increase.

•  The load capacity of  the engine is frequently

exceeded.

Too much valve lash can cause broken valve stems,

springs, and spring retainers. Too much valve lash

can be an indication of the following problems:

The blowby on a worn engine may be two times or

more than the blowby of  a new engine and may

indicate the need for an overhaul.

•  Worn camshaft and valve lifters

•  Worn rocker arms

•  Bent pushrods

•  Broken socket on the upper end of a pushrod

•  Loose adjustment screw for the valve lash

This document is printed from SPI². Not for RESALE

KENR8772

63

Testing and  Adjusting Section

If the camshaft and valve lifters show  rapid wear,

look for fuel in the lubrication oil or dirty lubrication

oil as a possible cause.

3.  Measure the valve lash for the valve when the

engine is at TC compression stroke according to

Table 8. If necessary, adjust the valves according

to Table 8.

Valve Lash Check

a.  Loosen the valve adjustment screw locknut

that is on the adjustment screw.

An adjustment  is NOT NECESSARY if  the

measurement of the valve lash is in the acceptable

range. Check the valve lash  while the engine is

stopped. The temperature of the engine does not

change the valve lash setting.

b. Place an appropriate feeler gauge between the

rocker arm and the valve. Turn the adjustment

screw while the valve adjustment screw locknut

is being held from turning. Adjust the valve lash

until the correct specification is achieved.

If the measurement is not  within the acceptable

clearance, adjustment is necessary. Refer to “Valve

Lash Adjustment”.

c.  After each adjustment, tighten the  valve

adjustment screw locknut while you hold the

valve adjustment screw from turning.

Valve Lash Adjustment

4.  Rotate the crankshaft in the direction of engine

rotation to TC exhaust stroke (360 degrees from

TC compression stroke).

Table 7

Inlet Valves

Exhaust Valves

0.48  mm

(0.019 inch)

0.48  mm

(0.019 inch)

Table 9

Valve Lash

TC Exhaust

Inlet Valves

Exhaust Valves

TC Compression

Stroke

Stroke(1)

Valve Lash

Cylinders

1-2-4

3-5-6

1-3-5

2-4-6

0.48  mm

(0.019 inch)

0.48  mm

(0.019 inch)

TC Exhaust

Stroke

(1)

3-5-6

2-4-6

Firing Order

1-5-3-6-2-4

(2)

(1)  360° from TC compression stroke

(1)  360° from TC compression stroke

(2)  The No. 1 Cylinder is at the front of the engine.

5.  Measure the valve lash for the valves when the

engine is at TC exhaust stroke according to Table

9. If necessary, adjust the valves  according to

Table 9.

Accidental  engine  starting  can cause  injury  or

death to personnel.

a.  Loosen the valve adjustment screw locknut

that is on the adjustment screw.

To prevent accidental engine starting, turn the ig-

nition switch to  the OFF position and place  a do

not operate tag at the ignition switch location.

b. Place an appropriate feeler gauge between the

rocker arm and the valve. Turn the adjustment

screw while the valve adjustment screw locknut

is being held from turning. Adjust the valve lash

until the correct specification is achieved.

1.  Remove the valve mechanism cover. Refer to

Disassembly and Assembly, “Valve Mechanism

Cover - Remove” For the removal procedure.

c.  After each adjustment, tighten the  valve

adjustment screw locknut while you hold the

valve adjustment screw from turning.

2.  Rotate the crankshaft in the direction of engine

rotation until the inlet valve of the No. 6 cylinder

has opened and the exhaust valve of the No. 6

cylinder has not completely closed. The engine is

now at TC compression stroke.

6.  Install the valve mechanism cover.  Refer to

Disassembly and Assembly, “Valve Mechanism

Cover - Install” for the installation procedure.

Table 8

TC

Compression

Stroke

Inlet Valves

Exhaust Valves

0.48  mm

(0.019 inch)

0.48  mm

(0.019 inch)

Valve Lash

Cylinders

1-2-4

1-3-5

This document is printed from SPI². Not for RESALE

64

KENR8772

Testing and  Adjusting Section

i04201709

For the wear limits for the inlet valves and exhaust

valves, refer to Specifications, “Cylinder Head”.

Valve Depth - Inspect

5.  Check each valve for cracks. Check the stems of

the valves for wear. Ensure that the valves are the

correct fit in the valve guides. Refer to Systems

Operation, Testing and Adjusting, “Valve Guide

- Inspect” for the procedure to inspect the valve

guides.

Table 10

Required Tools

Tool

A

Part Number

21825617

21825496

Part Description

Dial gauge

Dial gauge Holder

Qty

1

6.  Check the load on the valve springs. Refer  to

Specifications, “Cylinder Head Valves” for the

correct lengths and specifications for the valve

springs.

B

1

i04201679

Valve Guide - Inspect

Perform this test in order to determine if a valve guide

should be replaced.

1.  Clean valve guides with soap, water, and a nylon

brush.

2.  Position an inspection light at the bottom of valve

guide bores. Inspect bores for burning or cracks.

Replace any damaged valve guides.

3.  Measure the inside diameter of each valve guide

with a ball gauge or small hole gauge set and an

outside micrometer.

g01201916

Illustration 54

Typical example

4.  If valve guide bore, taper, or out of round exceeds

the correct specification,  replace the valve

guide. Refer to Specifications  for the correct

specifications.

1.  Ensure that the faces of the valves are clean.

Ensure that the bottom face of the cylinder head

is clean. Ensure that the  cylinder head is not

distorted. Refer to Systems Operation, Testing

and Adjusting, “Cylinder Head - Inspect” for the

procedure to measure flatness of the  cylinder

head.

5.  Measure the valve guides  within 0.64 mm

(0.025 inch) of each end and 90 degrees  from

crankshaft center line. Record the measurements.

Determine the valve stem-to-guide  running

clearance after inspecting the  cylinder head

valves.

2.  Use the Tooling (A) to check the depths of the inlet

valves and the exhaust valves below the face of

the cylinder head. Use Tooling (B) to zero Tooling

(A).

3.  For the minimum and maximum limits for a new

engine for the inlet valves and the exhaust valves,

refer to Specifications, “Cylinder Head”.

4.  Service wear occurs on an engine which has

been in operation. If the valve depth below  the

cylinder head face on a used  engine exceeds

the specification for service wear, the following

components must be replaced.

•  Valves

•  Valve inserts

This document is printed from SPI². Not for RESALE

KENR8772

65

Testing and  Adjusting Section

Lubrication System

Engine Oil Pressure - Test

Low Oil Pressure

Table 12

Minimum Expected Oil Pressure with  Lubricant

Viscosity of  10W30

i04205309

Sales Model

Engine Speed

(rpm)

Pressure

1600D

1600D

1600A

1600A

1500

1800

1500

1800

221 kPa (32 psi)

228 kPa (33 psi)

241 kPa (35 psi)

255 kPa (37 psi)

The following conditions will cause low oil pressure.

•  The oil level is low in the crankcase.

A suitable pressure gauge can be used in order to

test the pressure of the lubrication system.

•  A restriction exists on the oil suction screen.

•  Connections in the oil lines are leaking.

•  The connecting rod or the main bearings are worn.

•  The rotors in the oil pump are worn.

High Oil Pressure

High oil pressure can be caused  by the following

condition.

•  Excessive sludge exists in the oil which makes the

viscosity of the oil too high.

•  The oil pressure regulating valve  is operating

incorrectly.

i04201372

A worn oil pressure regulating valve can allow oil to

leak through the valve which lowers the oil pressure.

Visually inspect the pressure regulating valve  for

damage. If the pressure regulating valve is damaged,

the pressure regulating valve must be replaced.

Engine Oil Pump - Inspect

If any part of the oil pump is worn enough in order to

affect the performance of the oil pump, the oil pump

must be replaced.

The pressure regulating valve operates at a pressure

of 331 kPa (48 psi).

Perform the following procedures in order to inspect

the oil pump. Refer to Specifications, “Engine  Oil

Pump” for clearances and torques.

Refer to tables  11 and 12 for the  minimum oil

pressure at certain engine speeds and at  normal

operating temperature. A lower pressure is normal

at low idle.

1.  Remove the oil pump from the engine. Refer to

Disassembly and Assembly, “Engine Oil Pump -

Remove” for the correct procedure. Remove the

cover of the oil pump.

Table 11

Minimum Expected Oil Pressure with  Lubricant

Viscosity of  15W40

Sales Model

Engine Speed

(rpm)

Pressure

1600D

1600D

1600A

1600A

1500

1800

1500

1800

234 kPa (34 psi)

234 kPa (34 psi)

255 kPa (37 psi)

255 kPa (37 psi)

This document is printed from SPI². Not for RESALE