93-94 ENGINEFOREWORD This publication is intended to provide technicians and service personnel with the latest technical advancements incorporated in the 7.3L IDI Turbocharged Diesel Engine. The information con- tained in this publication will supplement information contained in available service literature. IMPORTANT SAFETY NOTICE Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles, as well as the personal safety of the individual doing the work. This manual provides general directions for accomplishing service and repair work with tested, effective techniques. Following them will help assure reliability. There are numerous variations in procedures, techniques, tools, and parts for servicing vet ‘as well as in the skill of the individual doing the work. This manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Accordingly, anyone who departs from the instructions provided in this manual must first establish that he comprises neither his personal safety nor the vehicle integrity by his choice of methods, tools or parts. The following list contains some general WARNINGS that you should follow when you work on a vehicle. + Always wear safety glasses for eye protection. * Use safety stands whenever a procedure requires you to be under the vehicle. * Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure. + Never perform any service to the engine with the air cleaner removed and the engine running unless a turbocharger compressor inlet shield is installed. Reference instructions on page 36. * Set the parking brake when working on the vehicle. If you have an automatic transmission, set it in PARK unless instructed otherwise for a specific service operation. If you have a manual transmission, it should be in REVERSE (engine OFF) or NEUTRAL (engine ON) unless instructed otherwise for a specific service operation. * Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide. + Keep yourself and your clothing away from moving parts when the engine is running, especially the fan, belts, and the turbocharger compressor. * To prevent serious burns, avoid contact with hot metal parts such as the radiator, turbocharger pipes, exhaust manifold, tail pipe, catalytic converter and muffler * Do not smoke while working on the vehicle. * To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle. Tie long hair securely behind the head. * Keep hands and other objects clear of the radiator fan blades.TABLE OF CONTENTS. 7.3 LITER IDI TURBOCHARGED DIESEL ENGINE INTRODUCTION. OPTIONAL IN F'SERIES TRUCKS: 7.3L-7.31 IDI TURBOCHARGED COMPARISON TURBOCHARGER BASIC FLOW & THEORY TURBOCHARGER LEGEND TURBOCHARGER LUBRICATION LEGEND POWER CURVE COMPARISON TORQUE CURVE COMPARISON SPECIFICATIONS CHART PHYSICAL IDENTIFICATION Engine Serial Number Calibration Label Emissions Label EXTERNAL FEATURES AIR CLEANER ASSEMBLY. TURBOCHARGER ASSEMBLY EXHAUST CROSSOVER PIPE ‘TURBOCHARGER PACKAGE. TURBOCHARGER ASSEMBLY TURSOCHARGER ID PLATE AIR RATIO. TURBINE AIR RATIO. CROSSOVER PIPE "Y" COLLECTOR EXHAUST INLET CASTING WASTEGATE WASTEGATE ACTUATOR MARMON CLAMP PEDESTAL, AIR CHAMBER OL MANIFOLD TURBOCHARGER OIL SUPPLY TURBOCHARGER OIL LINE HEAT SHIELDING TURBINEIEXHAUST HEAT SHIELD AIR CLEANER ASSEMBLY AIR CLEANER ELEMENT. FILTER MINDER VALVE COVERS LEFT VALVE COVER, RIGHT VALVE COVER, ENGINE WIRING HARNESS DESIGN MODIFICATIONS. INTERNAL PARTS CHANGES Head Gasket 1" u " 1 12 13 13 4 4 18 18 15 16 16 16 7 18 18 18 19 19 19 20 20 20 a Fl 21 22 23 2a 28 Turbocharged Power Cylinder Components Connecting Rod Piston Pin ‘Anodized Piston Had Piston Rings Keystone Design Ring Groove Measurement Exhaust Valve EXTERNAL MODIFICATIONS Ol Cooter Buncte Flywheel \ioration Damper Fuel Injection Pump Fue! Injection Nozzle Fuel Return Line ‘TURBOCHARGED ENGINE DIAGNOSTICS. DIAGNOSTIC FORMS. DIAGNOSTIC CHANGES BOOST TEST WASTEGATE ACTUATOR TEST AIR FILTER RESTRICTION TEST. INJECTION PUMP TIMING TEST INJECTION PUMP TIMING. INJECTION PUMP TRANSFER PRESSURE TEST NOZZLE TEST CRANKCASE PRESSURE TEST SERVICE TIPS. TURBO REMOVAL ‘TURBO INSPECTION Cheek End Play Check Radial Movement ‘TURBO COMPONENT REPLACEMENT Center Section Replacement Weastegate Actuator Removal Wastegate Actuator Installation Turbo installation Injection Pump Removal Injection Pump Installation Torque Angle Test Air Induction CHASSIS CHANGES. BUMPER SLOTS AIR DAM E400 DIPSTICK 40D MICROPROCESSOR EXHAUST SYSTEM FAN CLUTCH APPENDIX SERIAL NUMBER BREAK LISTING ENGINE PERFORMANCE CHART DIAGNOSTIC GUIDE Page 24 24 25 25 25 26-27 27 27 or 28 28 28.29 20 29 30 30 30 5032 32.04 34.35 35 35 3637 38 38-40 40 41-48 46 46 46 a7 47st 5152 5354 5459 59.60 60 61-63 63.65 65 65 66 er er Al a2INTRODUCING 7.3L IDI TURBOCHARGED DIESEL ENGINE INTRODUCTION7.3L IDI TURBOCHARGED DIESEL ENGINE F-SERIES The 7.3L IDI Turbocharged Diesel Engine will be optional in the F-Series trucks 37.3L IDL TURBOCHARGED DIESEL ENGINE The purpose of this publication i supplement aveieble 7-9 7.3L-7.3L IDI TURBOCHARGED DIESEL jesel Engine service literature and to introduce he 7.3L IDI ENGINE COMPARISON OVERVIEW Turbocharged Diesel Engine highlighting the following areas: ROWER ANDITQRGUE: CURVES *7.3L-7.SL IDI Turbocharged rae) Diesel Engine Comparison Overview 7.3L IDI TURBOCHARGED DIESEL — Power and Torque ENGINE PHYSICAL IDENTIFICATION —Spectfications — VEHICLE * 7.3L IDI Turbocharged Diesel Engine Physical Identification Vehicle —Engine * Engine Internal Changes — ENGINE ENGINE INTERNAL CHANGES PERFORMANCE DIAGNOSTICS GLEN =i Ue NT) Ges eee INTERCHANGEABILITY ¢ Performance Diagnostics A)" (ola) * Parts Identification and eaten Interchangeabilty * Service Tips — 7.3L IDI TURBOCHARGED DIESEL —7.3L Engines ENGINE —7'31 IDI Turbocharged Diesel Engines 7.3L DIESEL ENGINE UPDATE + 7.3L Diesel Engine Update — IMPROVEMENTS SINCE LAST — Improvements Since Last UPDATE (SEPTEMBER 1987) Nesin (epee S27}TURBOCHARGER BASIC FLOW AND THEORY rh irra 1 SS cre rt) Eg Panta anirouo rie Toa} 7.3L IDI eran A turbocharger is a relatively simple air pump used to increase the volume and density of air available for combustion in an engine. turbocharger consists of a turbine, which is driven by exhaust gases exiting the engine. This turbine is attached to the compressor by a common shaft supported by two bushings. Turbocharger operation raises the pressure delivered to the combustion chamber. This increase in air pressure presented to the combustion chamber with the properly metered quantity of fuel results in an increase in engine performance and efficiency. This feature will allow the engine to deliver rated levels of performance, irrespective of atmospheric conditions up to 10,000 feet elevation.TURBOCHARGER TURBOCHARGER WASTEGATE ACTUATOR COMPRESSOR (COLD) WHEEL at in) WASTEGATE os COMPRESSOR // HOUSING ms mast (HOT) WHEEL HOUSING LEGEND * DARK BLUE COMPRESSED AIR ARK RED =— EXHAUST INLET *LIGHT RED =— EXHAUST OUTLET © WHITE — WASTEGATETURBOCHARGER TURBOCHARGER LUBRICATION Ol. SUPPLY BEARINGS LEGEND * GREEN — OIL SUPPLY * YELLOW — RETURN OIL7.3L IDI TURBOCHARGED DIESEL ENGINE POWER CURVE COMPARISON The 7.3L IDI Turbocharged Diesel Engine will consistently deliver 190 hp at 3000 rpm rated speed up to elevations of 10,000 feet. Pa Dee CoC as TORQUE CURVE COMPARISON The 7.3L IDI Turbocharged Diesel Engine produces a peak torque of 388 Ib./it. at 1400 R.P.M. compared to the 7.3 naturally aspirated’s 338 Ib./I. on 1988-1992 engines and 358 Ib.ift. on 19927 engines * The 7.3L IDI Turbocharged Diesel Engine provides a significant increase in performance, altitude compensation and torque capability without sacrificing reliability of the drive train components a erat * A natural aspirated engine suffers a 3% loss of power per 1,000 feet of elevation above sea level * A 185 hp engine at 6,000 feet has a 33 hp loss of power * Some engine manufacturers also advertise a loss of power for every 1,000 feet of elevation above 5,000 feet on their turbocharged engines EA SMe ae UCT7.3L IDI TURBOCHARGED DIESEL ENGINE SPECIFICATIONS Dymond Cra Cra COTES ATTN Ea ASPIRATION TURBOCHARGED use 190 @ 3000 Pavano ta 5 @ 1400 ecu ie en claha nim rT faeries ee meu Sua Smee) TOTAL ENGINE WEIGHT (DRY) EoTes Weg eR OCA rr FAN-TO-CRANK-RATIO 14st Penis elen) eau) Ua Meeks La Cee) EXHAUST FLOW cre CoeloMN eM aiaooun A (eI eT) 10US. QUARTS: LUBRICATING-SYSTEM CAPACITY (INCLUDING FILTER) STEM GLE 13 The 7.3L IDI Turbocharged Diesel Engine is a four-cycle 90 degree block design with pushrod operated overhead valves. The engine has a displacement of 7.3 liters (444 cubic inches). 7.3L IDI Turbocharged Diesel Engine specifications are provided in Figure 9. ENGINE TYPE DIESEL,4-CYCLE CONFIGURATION OHV V8 DISPLACEMENT 444 cu. in BORE AND STROKE . * 4.11 x 4.18 in. COMPRESSION RATIO. 21.5:1 ASPIRATION : TURBOCHARGED RATED POWER @ RPM. : - +190 @ 3000 PEAK TORQUE @ RPM 385 @ 1400 ROTATION, FACING FLYWHEEL, : COUNTERCLOCKWISE COMBUSTION SYSTEM SWIRL CHAMBER TOTAL ENGINE WEIGHT (DRY) : 900 LB. WATER FLOW @ 3000 RPM 79 gpm FAN-TO-CRANK-RATIO * LAfh HEAT REJECTION 47 BTUIHP MIN AIR FLOW @ 3000 RPM 430 cm EXHAUST FLOW........ i =. 1250 cfm COOLING-SYSTEM CAPACITY (ENGINE ONLY) 10 U.S. QUARTS LUBRICATING-SYSTEM CAPACITY (INCLUDING FILTER) 10 U.S. QUARTS7.3L IDI TURBOCHARGED DIESEL ENGINE PHYSICAL IDENTIFICATION ENGINE SERIAL NUMBER ENGINE SERIAL NUMBER The 7.3L IDI Turbocharged Diesel Engine can be identified by the following * Engine SIN * Calibration Label * Emissions Label © External Features CALIBRATION LABEL The calibration label located on the injection PS PUMP Gear tower provides easy identification of Y 7.3L IDI Turbocharged Diesel Engines. The WI code is as listed, Rar) © 389T-RO0 EMISSION ABEL EMISSIONS LABEL The emissions label located on the left valve cover provides identiication of the 7.3L IDI Turbocharged Diese! Engine. The engine model is identified as listed * Turbocharger Model AT190EXTERNAL FEATURES DS ASSEMBLY. ee mee TURBOCHARGER: 18 Figures 17, 18 & 19 identity external features of the 7.3L IDI Turbocharged Diesel Engine. Inoluded are the air cleaner assembly, turbocharger assembly and crossover pipe.12 TURBOCHARGER PACKAGE TURBO PACKAGE The turbocharger package features a Garrett Turbocharger matched to the exhaust gas flow of the engine and features: © A special “Y"' collector to direct exhaust gas flow to the turbocharger * An exhaust inlet casting to the turbocharger to direct exhaust gases to drive the turbine wheel * A waste gate to protect the turbocharger from overspeed by modulating boost pressure * An air chamber to direct compressed air into the intake manifold and onto the cylinders for combustionTURBOCHARGER PACKAGE TURBOCHARGER ASSEMBLY GARRETT 1-3 The name plate on the turbocharger identifies the part number and component serial number. TURBOCHARGER ID PLATES Pes The Garrett T-3 turbocharger allows the engine to operate up to 10,000 ft. elevation with no loss of power. Intake manifold pressure (boos!) will be modulated through the use of a wastegate. TURBOCHARGER) Te Nt The part number of the turbocharger should always be verified whenever replacement is performed by comparing part numbers on the name plates, 13TURBOCHARGER PACKAGE A/R RATIO IS A COMPARISON OF THE TURBINE NOZZLE CROSS SECTION AND THE RADIUS OF THE TURBINE GAS FLOW. AIR RATIO Exhaust turbine A/R ratios determine turbine wheel speed Small AIR ratios—high turbine wheel speed. Large AJR ratios—low turbine wheel speed. @ SMALL A/R RATIOS-HIGH TURBINE SPEEDS @ LARGE A/R RATIO-LOW TURBINE SPEEDS AIR RATIO The .82 AIR ratio allows high turbine wheel speeds at low engine speeds. This A/R ratio provides the best balance and match of performance at all speeds. The AIR ratio should always be verified when a turbocharger is replaced, TURBINE A/R RATIO. 14_ TURBOCHARGER PACKAGE MANDREL BENT EXHAUST CROSSOVER PIPE CROSSOVER PIPE ‘The crossover pipe is a single piece, mandrel bent to decrease exhaust restriction and to provide adequate clearance between the oil pan, flywheel cover and transmission mounting bolts. “¥" COLLECTOR The “Y” collector features a special design which optimizes exhaust pulsations and fiow characteristics to the turbocharger. This. feature also prolongs turbocharge’ life. Io GUS eae COLLECTOR 27 EXHAUST INLET CASTING The turbocharger exhaust inlet casting’s design directs the exhaust gases entering the turbine for optimum performance of the turbine wheel INLET CASTING 15TURBOCHARGER PACKAGE WASTEGATE WASTEGATE The wastegate regulates maximum speed ot the turbocharger by allowing excess exhaust gases to bypass the turbine housing and be directed into the exhaust stream to atmosphere. WASTEGATE ACTUATOR The wastegate actuator is a spring loaded diaphragm acted on by manifold pressure Manifold pressure assists in opening the wastegate, spring pressure closes the wastegate. Exhaust pressure in the turbine housing also assists in opening the wastegate. ‘* Wastegate actuators obtained through service parts will have to be adjusted should replacement be required. MARMON CLAMP The exhaust outlet and exhaust downpipe are connected together with a Marmon clamp. Marmon type clamps provide superior sealing of exhaust gases versus slip joint type connection. 31 16TURBOCHARGER PACKAGE UCONN SAINTE} PEDESTAL/OIL RETURN Olan b1=slle CBA @ NO EXTERNAL PENNS PEDESTAL The opening in-the intake manifold and the oil drain opening at the compressor housing are sealed by Viton “O" rings that ft into the pedestal. uae ee DO NOT USE OLB:C rs PEDESTAL The turbocharger mounting/oil drain pedestal attaches to the rear of the intake manifold This design eliminates the need for an external oil drain line. AON VO uN ty PEDESTAL/OIL RETURN ‘ Pichia Nes [gale aisle a PNPM aos PEDESTAL A special grommet secured in the valley pan seals the return oil drain NOTE: DO NOT attempt to use old COR grommet to seal turbo oil drain. 7TURBOCHARGER PACKAGE AIR CHAMBER The air chamber is designed to provide the op- timum swirl for equal air distribution to all oytinders, * A conventional type, Viton "0" Ring seals the air chamber to the compressor housing * The air chamber is sealed to the intake manifold by a square cut “‘O" ring seal * A copper seal washer is also used on the hold down bolt TURBOCHARGER OIL MANIFOLD 8) DuUiactelent atelsi ol SUN OMe Stele es ats =D) TURBOCHARGER OIL SUPPLY The turbocharger is supplied lube oil from the oil galley at the former oll pressure sender location, 18 Ox ailta Avis © 3SEA\ OIL MANIFOLD ‘An oil manifold is located on the oil niet side f the turbocharger center section. This manifold features two ports for attaching the following: © Turbocharger oil supply line * Engine oil pressure sender TURBO OIL SUPPLY LINETURBOCHARGER PACKAGE TURBOCHARGER OIL LINE A formed steel line is used to supply oil to the turbocharger center section. HEAT SHIELDING Heat shields made with fiberglass, encased in stainless steel, over the turbine housing and exhaust inlet casting are also part of the turbocharger package. (asaya ei) Riis TURBINE/EXHAUST HEAT SHIELD HEAT SHIELDING The heat shielding is formed to the exterior shape of the area which it covers, The heat shielding is secured to the turbocharger by one (1) boit in the exhaust inlet casting, band clamps and pins with clips. Heat shielding is on the crossover pipe and rear of the left exhaust manifold 19AIR CLEANER ASSEMBLY AIR CLEANER ASSEMBLY The air cleaner assembly is positioned on the engine over the left bank injection lines. The lower housing is bolted to the intake manifold, The upper housing is secured to the lower housing with studs and nuts. Both housings are cast aluminum. AIR FILTER ELEMENT © PLEATEDMPAPER WITH WDSc RUEY ONE zoe Meneame SHORTER LIFE FILTER MINDER ‘A filter minder gauge is mounted in the ‘clean ait” side of the upper housing. This allows the User to monitor air cleaner element condition as it indicates when the element should be changed. The filter minder measures air flow restriction in the air fiter and is calibrated in inches of water. 20 AiR CLEANER COMPONENTS © CAST ALUMINUM Seu Uo MECC 0 cel) AIR CLEANER ELEMENT The air cleaner element is a pleated paper panel type and features expanded foam fiter media attached to the bottom of the paper. This filter has specifically been designed to provide adequate fiter life Note: Non-Ford Motorcraft replacement filters may result in significantly shortened fiter lite and dirt ingestion AIR FILTER RESTRICTION GAUGE Caaseat Seen NS to} eae Toy Prat Ho) eer Us et 30 in. HzOVALVE COVERS ama LEFT VALVE COVER The left valve cover on the 7.3L IDI Turbocharged Diesel Engine has the Crankcase Depression Regulator (CDR) valve mounted on it. A formed reinforced rubber hose connects it to the air cleaner upper housing by clamps. NSD Ie sag ANF 7-15 LEFT VALVE COVER ‘The left valve cover is baffled to prevent excessive oil carry over from valve train oil splash. RIGHT VALVE _ COVER sj RIGHT VALVE COVER The right valve cover has a bracket welded on it for glow plug controller mounting. i foi eMC) EiyXeidal 24ENGINE HARNESS The turbo engine harness is made to conform to the relocated glow plug controller and is routed side to side at the front of the engine. INV mete NigloNuns§ me Tesla soley wy ON ON MCL Co) el ATI SS)DESIGN MODIFICATIONS ENHANCEMENTS * ii ene eam Design modifications have been incorporated into the internal engine components to withstand the pressures of turbocharging without compromising engine reliabiity or durability. Modifications referred to include: * Cylinder Head Gasket * Connecting Rod * Piston * Piston Pin * Rings © Exhaust Valve Although not internal, modifications have also been made to: © Oil Cooler Bundle * Flywheel * Vibration Damper © Fuel Injection Pump * Injection Nozzle 23HEAD GASKET The head gasket on the 7.3L IDI Turbocharged Diesel Engine has a heavier fire ring and armor wrap to withstand higher firing pressures and combustion temperature, The turbocharged head gasket can be identified by the notch in the gasket on the bottom (exhaust manifold) side. CONNECTING ROD To provide additional strength for the increased horsepower output, the connecting rod has a large wrist pin bore and large wrist pin bushing. The pin bore diameter has been increased from 1.1108” to 1.3086” a 17% increase. Seach Cour TURBOCHARGED POWER CYLINDER COMPONENTS Significant design changes have been made to the power cylinder components of the 7.3L IDI Turbocharged Diesel Engine. ie rentedINTERNAL PARTS CHANGES PSU Tp TURBO ANODIZED PISTON HEAD The piston head for the 7.3L IDI Turbocharged Diesel Engine is anodized Anodizing is an electrostatic coating process by which aluminum oxide is applied to the head of the piston. The anodized surface is more resistant to cracks caused by the increased firing pressures and combustion temperatures associated with turbocharging © IMPROVES RING LIFE Gira ensuireh dic} PISTON PIN The piston pin for the 7.3L ID! Turbocharged Diesel Engine is larger in diameter. 1.308” vs. 1.110” This 179% increase in diameter assures reliability of the piston pin in the turbocharged 7.3L. PISTON HEAD TURBO PISTON RINGS KEYSTONE DESIGN The top and intermediate ring on the 7.3L IDI Turbocharged Diesel Engine are keystone design. Top ring is 159 Second ring is. 6? Oil control ring is rectangular. Keystone rings are a premium heavy duty diesel feature that complements turbocharging which improves ring life and decreases the Potential for ring sticking. 25INTERNAL PARTS CHANGES RING GROOVE MEASUREMENT The Keystone top ring groove wear is measured by inserting specific gauge pins in the ring groove and measuring across the pins with an outside micrometer. RING GROOVE MEASUREMENT The intermediate Keystone top ring groove wear is measured by inserting specific gauge pins in the ring groove and measuring across the pins with an outside micrometer. 26 KEYSTONE RING GROOVE DS Via SU 0s\e Lelaintneieley 3 GAUGE PIN DIAMETER 115 in RING GROOVE MEASUREMENT The top ring groove is measured over 0.115” gauge pins. Upper limit—4.130" Lower limit—4.097" The gauge pins can be ordered from 0.1.C. Tool #ZTSE 3020-1 KEYSTONE RING GROOVE MEASUREMENT Me giil=o) We Neel toLoN" GAUGE PIN DIAMETER .098 inINTERNAL PARTS CHANGES Casa LOWER LIMIT 4.1357” EXHAUST VALVE The exhaust valve used in the 7.3L IDI Turbocharged Diesel Engine is made of Inconel alloy and the valve stem is full chrome plated. Inconel alloy provides greater corrosion resistance and fatigue strength at the higher temperatures of the turbocharged engine. The turbocharger exhaust valve can be identified by the dimple and part number on the head of the valve This valve has same 37.5° face angle. 30 FINS Couoi] RING GROOVE MEASUREMENT The intermediate ring groove is measured over 0.098" gauge pins. Upper limit 4.160” Lower limit 4.135" ‘The gauge pins can be ordered from OTC. Tool #ZTSE 3020-3, EXHAUST VALVES millit=fo} “INCONEL ALLOY IMPROVES FATIGUE STRENGTH Bierce eel oN SNe 59 OIL COOLER BUNDLE The oil cooler bundle on the 7.3L IDI Turbocharged Diesel Engine has increased fin density for adcitional heat dissipation. 30 Fins Per Inch on the Turbocharged version versus 24 Fins per inch on the NA. Engine. 27EXTERNAL MODIFICATIONS FLYWHEEL Heavier engine components change the engine balance and require use of “Turbocharger” specific flywheels for manual and automatic transmissions. Manual F3TZ6375A Auto 1816637C1 ‘These changes are not discernible other than by the part number. DYN) FUEL INJECTION PUMP The external appearance of the Stanadyne Model DB2 injection pump is unchanged. * Calibration of the pump complements turbocharging and is necessary to attain desired engine performance and meet emissions standards. 28 fa AUB} Carri VIBRATION DAMPER Changes in engine balance require a different value of harmonic balance of the vibration damper. Turbocharged P/N 1816624C1 N/A PIN 1809117C1 Physical differences in the vibration damper are iilustrated, NOTE: vibration dampers cannot be interchanged. @ CALIBRATED FOR TURBO! © NOT FOR N/A Nei TaEXTERNAL MODIFICATIONS TSP =tey To AU) ga eV) 10, Onramninn crn Bitoni Cerro FUEL INJECTION NOZZLE The fuel injection nozzle used on the turbo engine is a “G" code, The visual appearance is the same as the N.A. engine's "E” code. The flow characteristic of the nozzle is tailored for the turbocharged engine. NOZZLE/RETURN) FUEL HOSES Ceesso rs Ia iE rar Vatu FUEL INJECTION PUMP ‘The injection pump |.D. tag shows the Navistar part number. Always verify part number should the pump be changed * Do not use this pump on natural aspirated engines INJECTION NOZZLES TURBO” ny Gren PNG IbYVe Nels uss FUEL RETURN LINE The nozzle return fuel line crossover has been relocated trom the rear of the engine to the front of the air intake plenum to protect the line from the turbocharger exhaust system heat. 29TURBOCHARGED ENGINE DIAGNOSTICS 67 DIAGNOSTIC FORMS We will continue to evaluate engine performance through the use of a diagnostic form, with Procedures expanded for testing of boost and the wastegate actuator. DIAGNOSTIC CHANGES Engine performance diagnostics have changed on the turbocharged 7.3, * Addition of boost test * Addition of wastegate actuator test * Safety concerns during transfer pump test * Revised injection nozzle test specification * Air cleaner restriction BOOST TEST Boost test has been added to the diagnostic form for the turbocharged 7.3. 30TURBOCHARGED ENGINE DIAGNOSTICS Basle Sea BOOST TEST Remove air cleaner assembly. Garner ions.) ie) Mr ole) a0 ee BOOST TEST Remove pipe plug, install adapter and hose connecting to gauge bar to obtain boost measurement, Seema Gadi TURBO BOOST TES: BOOST TEST Re-install air cleaner assembly AIR CLEANER REMOVED. DEC Rel 0 se DO NOT PERFORM BOOST TEST WITH 31TURBOCHARGED ENGINE DIAGNOSTICS TURBO BOOST TEST BOOST TEST MIN. § PSI Position gauge bar set in the cab of the truck where gauge reading can be observed. BOOST TEST On units with automatic transmission, perform PARC ‘i i 3 a convertor stall test (1680-2100 rpm). feel RO ‘5 psi min. should be observed. On units CANS) with manual transmission and in second gear IoaR el Ea at 1200 rpm accelerate to 2800 rpm, Serer) 5 psi min. should be observed. * Stall speed listed is for E40D transmission only WASTEGATE ACTUATOR TEST Wastegate Actuator Test has been added to the diagnostic test form. 32TURBOCHARGED ENGINE DIAGNOSTICS 7 Bw aes AES er Nias AP a © 30 PSI GAUGE WASTEGATE ACTUATOR TEST Start of rod travel movement should be observed at 12-15 psi applied via hand pressure pump, Conc WASTEGATE ACTUATOR TEST Connect hand pump and 0-30 psi gauge to actuator. WASTEGATE ACTUATOR TEST CRITERIA 00 Doe © 12/15 PSI START OF aie =n WASTEGATE ACTUATOR TEST No further rod travel should be observed after 20-22 psi has been applied via hand pressure pump. Total rod movernent is less than 500!” 33TURBOCHARGED ENGINE DIAGNOSTICS WASTEGATE ACTUATOR TEST The 20-22 psi should be maintained for 30 seconds with no decay. This verifies diaphragm condition It pressure decay occurs, replace actuator PIS sere NPN cae WASTEGATE FREEDOM Careers ae peers AIR FILTER RESTRICTION TEST With the increased air flow requirements of the turbocharged engine, air filter restriction becomes more important to the actual performance of the vehicle, 34 WASTEGATE ACTUATOR A ia ea Te EA I om WITH NO DECAY WASTEGATE ACTUATOR TEST If wastegate does not move, remove actuator rod from wastegate and check wastegate for freedom of movement. If wastegatge moves freely, replace actuator. If wastegate does not move, spray shaft and lever area with WD40 or equivalent. If wastegate cannot be freed up, the wastegate housing will have to be removed for repair or replacement.TURBOCHARGED ENGINE DIAGNOSTICS AIR FILTER RESTRICTION TEST Change air filter element when restriction gauge indicates a fully deployed flag or when 30 inches of water restriction is measured with ‘© ROTUNDA GAUGE BAR a magnahelic gauge. MAGNAHELIC GAUGE MAY TALON =ogg NIGH Cars nn INJECTION PUMP TIMING TEST INJECTION PUMP TIMING Injection pump dynamic timing on the 7.3L IDI Turbocharged Diesel Engine is the sare as the 7.3 N.A. engine 8+ 2° BT.D.C. @ UNCHANGED 2000 rpm with the Rotunda timing meter 8°t 2°e 2000 RPM 078-0020. Timing is by the line pulse method with Rotunda adapter 078-00201 35TURBOCHARGED ENGINE DIAGNOSTICS INJECTION PUMP TRANSFER PRESSURE TEST SU a TRANSFER PRESSURE TEST Since the air cleaner assembly must be Temoved to perform this test, a guard should be used on the compressor wheel opening to protect the turbocharger from object damage. TRANSFER PRESSURE TEST A guard from OTC P/N JDGS76 can be used or a guard may be made locally 36TURBOCHARGED ENGINE DIAGNOSTICS Domenie aca TRANSFER PRESSURE TEST With transfer pump adapter connected to the 0-160 psi gauge, run the engine at 3000 rpm. BSG ae y ) Ee TRANSFER PRESSURE TEST [wii While the engine is at 3000 rpm, observe eens gauge reading. Spec. 90-120 psi NOZZLE TEST Nozzle testing should only be performed if the engine has a cylinder miss or is running roughly. 37TURBOCHARGED ENGINE DIAGNOSTICS NOZZLE TEST Nozzle Test Specs. New or reconditioned nozzles opening pressure is 1900+ 75 psi Minimum pressure on used nozzles before replacement is 1450 psi CRANKCASE PRESSURE TEST The crankcase pressure test has changed due to the new location of the Crankcase Depression Regulator. Specification is unchanged. CRANKCASE-PRESSURE TES — CRANKCASE PRESSURE TEST To perform crankcase pressure test, loosen two COR mounting bolts. LOOSEN.CDR MOUNTING BOLTS 38TURBOCHARGED ENGINE DIAGNOSTICS Ee itl oa CRANKCASE PRESSURE TEST Remove oil fil cap. Install orifice restrictor tool and adapter. Col Cel NS SS ao aaa .———— ig J eabsso§ IN PARK eee ute Piya ya Peete ay CRANKCASE PRESSURE TEST Insert a small piece of cardboard between hose and CDR valve and tighten mounting botts. Cr Tareas xine CRANKCASE PRESSURE TEST With transmission in neutral (PARK) arid park brake set, stant engine and run engine at 3000 rpm. Observe reading on magnahelic gauge. Specification is 6 inches of water max. High crankcase pressure readings relate to power cylinder components in poor condition. Remember to remove cardboard blocking CDR valve after completing the test. 39SERVICE TIPS SERVICE TIPS TURBO REMOVAL/INSTALLATION COMPONENT REPLACEMENT ACTUATOR REMOVAL/INSTALLATION INJECTION PUMP REMOVAL/INSTALLATION TORQUING MAIN BEARING CAP BOLTS FLYWHEEL BOLTS + TURBOCHARGER ASSEMBLY REMOVAL AND RE-INSTALLATION * TURBOCHARGER CENTER SECTION REPLACEMENT * WASTEGATE ACTUATOR REPLACEMENT * INJECTION PUMP REMOVAL AND REPLACEMENT * TORQUING PROCEDURES — MAIN BEARING BOLTS — FLYWHEEL BOLT * AIR INDUCTION PRESSURE TEST 40SERVICE TIPS TURBO REMOVAL Listed are important steps to ease removal and installation of the turbocharger assembly, TURBO REMOVAL TURBO REMOVAL From under vehicle, remove two nuts, securing the crossover pipe flange to the left exhaust manifold REMOVE LEFT Seah TURBO REMOVAL From under vehicle, remove two ""Y"" collector mounting bolts from the right exhaust manifold bc Sate keane TO MANIFOLD BOLTS a1SERVICE TIPS TURBO REMOVAL TURBO REMOVAL Twist and pull down on crossover pipe to separate “Y"' collector from exhaust inlet casting. 102 TURBO REMOVAL TURBO REMOVAL Once separated, let crossover pipe rest loose under vehicle. > a REMOVAL TURBO REMOVAL Inside the engine compartment, after air cleaner has been removed, loosen the turbocharger's oll supply line nut at oil manifold Deon soap core ag a 104 42SERVICE TIPS TURBO REMOVAL TURBO REMOVAL Remove oil pressure sending unit wire. Bea OMe fea TUREO REMOVA} CLS ONe SMa Wee oN TURBO REMOVAL Loosen oil supply line nut at the rear of the engine, TURBO REMOVAL Remove oil supply line. Ea) ais oR Tae ars 43SERVICE TIPS TURBO REMOVAL Loosen Marmon clamp at exhaust outlet down pipe connection: By a « ) moles Mo We (oe Nie ii 108 TURBO REMOVAL Remove the two oil drainimounting pedestal bolts from the rear of the intake manifold, 109 TURBO REMOVAL Remove the air chamber hold down bolt. 44SERVICE TIPS TURBO REMOVAL With a screwdriver or small flat pry bar, lift turbocharger assembly out of grommet in valley pan. Ae Brtrs-ton = oy". TURBO REMOVAL Remove air chamber from the turbocharger ‘compressor outlet. Pen aoe NG TURBO REMOVAL Position the turbocharger towards the heater housing and remove the two nuts securing the center housing to the drain pedestal Era SToe Uae 13 45SERVICE TIPS TURBO-REMOVAL=—— TURBO REMOVAL Slide the drain pedestal off the center housing and lift turbocharger assembly out of ‘engine compartment = Sarat 14 CHECK END PLAY TURBO INSPECTION Remove wastegate housing and check turbocharger endplay by moving shaft back and forth. 001” ~ .004" is allowable. Yy RADIAL MOVEMENT TURBO INSPECTION Check turbocharger radial shaft movement by liting the shaft up and rotating the shatt to check for any compressor or turbine wheel to housing contact. if any wheel contact is noticed, the turbocharger must be replaced or repaired. 46SERVICE TIPS CENTER SECTION REPLACEMENT A center section will be available for service parts to expedite field repairs in conjunction with re-man turbos and individual component parts. 17 CENTER SECTION REPLACEMENT Scribe line on compressor housing and center section to reference during assembly. SORIBE COMPRESSOR HOUSING PORIBEFERENCE 18 CENTER SECTION REPLACEMENT ‘Also soribe reference marks on the turbine housing in order to ease re-assembly. ‘SCRIBETURBINE HOUSING FORREFERENCE 19 47SERVICE TIPS CENTER SECTION REPLACEMENT Remove compressor housing bolts and clamps. NaCl ecole} CENTER SECTION REPLACEMENT Separate compressor housing from turbocharger. Inspect for wheel rub. CENTER SECTION REPLACEMENT Remove turbine housing bolts and clamps. AGEN OMT Te) BOLTS AND CLAMPS 48SERVICE TIPS CENTER SECTION REPLACEMENT Visually inspect compressor and turbine wheels for damage. If wheel Gamage is observed, turbocharger will have to be repaired or replaced. SERVICE HARDWARE Coes CENTER SECTION REPLACEMENT Separate turbine housing from center section of turbocharger. Inspect for wheel rub. BTR ase ‘ Someta Leanne sstster wre Bre aira wh CENTER SECTION REPLACEMENT Hardware to attach compressor housing to center section includes bolts, clamps, and an “0” ring. 49SERVICE TIPS SST ela GPG TURBINE SIDE CENTER SECTION REPLACEMENT Hardware used to secure the turbine housing to the center section includes bolts and clamps Anti-Seize compound should be used when bolts are installed. CENTER SECTION REPLACEMENT Carefully install the center section into the turbine housings. Terme onesie eta) 15 IRC ales reps CENTER SECTION REPLACEMENT ‘After properly aligning turbine housing and center section, apply anti-seize compound to bolts, install and tighten. 50SERVICE TIPS CENTER SECTION REPLACEMENT Verity the position of the “O” ring and install compressor housing to center section. CENTER SECTION REPLACEMENT Align reference marks, then tighten compressor bolts. WOAy, TSN Treas te 10H Crees 130 REMOVE ALOU WASTEGATE ACTUATOR a A REMOVAL AND INSTALLATION INSTALLATION 131 51SERVICE TIPS ACTUATOR REMOVAL Remove clip which secures actuator rod to wastegate ACTUATOR REMOVAL Remove actuator bracket retaining bolts. ACTUATOR REMOVAL Remove boost signal hose from actuator canister. 52SERVICE TIPS SERVICE PART ACTUATOR INSTALLATION The new service part actuator is supplied with a locking collar on the control rod. The locking collar provides two functions: * Provides the correct pre-load on the spring * Protects the diaphragm during shipping and storage ACTUATOR INSTALLATION To install actuator, start by attaching boost signal hose to actuator canister. a7 NS Net uae O AGTUATOR 136 ACTUATOR INSTALLATION Install bolts securing actuator bracket to compressor housing. DS cs ona HOT it 53SERVICE TIPS ACTUATOR INSTALLATION On service replacement actuators with wastegate fully closed, adjust rod end to wastegate lever and install clip, Lock rod end in place. TURBO INSTALLATION To ease turbocharger installation, all mounting and exhaust joints will be loosely assembled until turbo is completely in place. Then all joints should be tightened. Following is the procedure: Position the oil drain mounting pedestal in vee of engine. Verify “0” ring seals are in place. 54 ACTUATOR INSTALLATION Remove lock collar from actuator rod when a service part replacement is being installed. MUTTON Le Vee WT) |SERVICE TIPS Atconcn uy TURBO INSTALLATION Position turbocharger in engine compartment, then slide pedestal up on studs in center housing of turbocharger TURBO INSTALLATION Install and tighten nuts to secure turbocharger to drain pedestal Tyme NPCs) Bit cob tutto ar Recon cis We glel aM TURBO INSTALLATION * Install air chamber on turbocharger * Position Marmon clamp on exhaust outlet flange * Verity large square cut “O" ring is on i a ‘ intake manifold RUSS Ae nse eL) ag RTT 55SERVICE TIPS TURBO INSTALLATION Position pedestal drain into grommet in valley pan and loosely install the two mounting mounting bolts at the rear of intake manifold Note: verity acceleratorlcruise cables are routed correctly and move freely Mccema ar t pan saa er yc 144 TURBO INSTALLATION TURBO INSTALLATION From under vehicle, position crossover pipe on left exhaust manifold and loosely install the two flange mounting nuts. Morsay ea Ue tea cl RTson aaNet) 145 IURBOYNSTALLATION TURBO INSTALLATION Using a long drift punch, tap * into turbine inlet casting collector 56SERVICE TIPS yf Nouaw TURBO INSTALLATION Install and tighten two bolts to secure “Y” collector to right exhaust manifold. (sero ules COLLECTOR TO RIGHT MANIFOLD 147 TURBO INSTALLATION: TURBO INSTALLATION Tighten two left exhaust manifold to crossover pipe flange mounting nuts 148 TURBO INSTALLATION Tighten the two oil drain/mounting pedestal bolts at rear of intake manifold. Ma glia Relay Tins <1 eel 57SERVICE TIPS TURBO INSTALLATION Position Marmon clamp on exhaust outlet casting and down pipe, then tighten clamp. S10) =O SU VEG) ec TURBO INSTALLATION Install turbocharger oil supply line and tighten nuts. eM TURBO BY LINE \) 151 TURBO INSTALLATION, TURBO INSTALLATION Install oil pressure sender wire. Ror oieaecs ace 152 58SERVICE TIPS TURBO INSTALLATION * Verify copper seal is on hold down bolt * Install hold down bolt and torque to 10 Ibs. ft. min.—20 Ibs. ft. max CAUTION: DO NOT OVERTIGHTEN. 153 FUEL INJECTION PUMP REMOVAL vA AND INSTALLATION ! mise oN Fuel injection pump removal and installation FANDIINSTALLATION, procedures on the 7.3L IDI Turbocharged r Diesel Engine change slightly when compared to current published procedures. INJECTION PUMP REMOVAL, Follow standard procedure for pump rémoval J and prior to sliding the pump rearward off the EX three mounting studs, pull fuel return ae Grossover line up out of the vee of the Cyan ee engine. GpEreTURNG Ms se eT Gon 59SERVICE TIPS INJECTION PUMP REMOVAL * Move pump rearward to oblain access to the top stud * Remove stud from gear housing as shown INJECTION PUMP REMOVAL * With a screwdriver or equivalent, pry rearward slightly and lift upward as shown * Pull injection pump with lines attached out of the engine compartment INJECTION PUMP INSTALLATION * After the pump has been positioned on the engine, re-install the top stud + Reposition fuel return crossover line down in the vee * Complete installation in accordance to published procedures 60SERVICE TIPS TORQUE ANGLE An additional turn of a fastener to a specified angle past its final torque. 159 MEER TORQUE fe se TORQUE ANGLE * Torque main bearing cap bolts by the published two step procedure * First Step — 75 Ibs. th * Second Step — 95 Ibs. ft. MAIN BEARING CAP BOLT TORQUE ii ire ce rac 161A TORQUE ANGLE Install angle meter and breaker bar to 5/8” socket. 61SERVICE TIPS MAIN BEARING CAP. BOLT TORQUE TORQUE ANGLE Tighten main bearing cap bolt an addtional 459 ‘An additional 1/8 of a tum is equal to 45° Ba Sa aw Lon Ro aw ick 2 162 TORQUE ANGLE Torque angle is also used on flywheel mounting bolts. Start by tightening bolts with a torque wrench to specified torque, 47 Ibs. ft SSC RES ohutol el aaa igoe NODS PAN (0 BOLT TORG TORQUE ANGLE Install angle meter and breaker bar on 5/8” socket, INS WaT at 164 62SERVICE TIPS TORQUE ANGLE Tighten flywhee! bolts an adaitional 45° ‘An additional 1/8 of a turn is equal to 45° ANNU ony oD). ac ela Nel 165 TEST AIR INDUCTION Pressure testing the air induction system verifies the integrity of the air intake system Nig Uc a Ae | and locates any leakage that might be in the system LOCATES LEAKAGE IN THE SYSTEM TEST AIR INDUCTION To pressure test the air induction system, modification to an air cleaner element will be required, * With duct tape or equivalent, cover the clean air side of the element 63SERVICE TIPS Tey to) ol aL =) TEST AIR INDUCTION The CDR hose has to be removed from the upper air cleaner housing. The spud opening has to be capped and clamped. TEST AIR INDUCTION * Install modified air cleaner element + Remove restriction gauge * Install pressure regulator in upper housing poe se SH REGULATOR vi IN HOUSING AT GAUGE LOCATION 169 TEST AIR INDUCTION With shop air connected to regulator valve, adjust to maintain 5-8 psi in the air induction heer system. NZ he PON UMC CONTAIN Besa Ii) 64SERVICE TIPS TEST AIR INDUCTION Spray all air induction system joints and connections with a soaphwater solution. NOTE: Mr. Bubble works very well * Inspect for blowing bubbles * Bubbles indicate air leakage Bry Me euch ane ‘* Slight leakage at compressor back Aen 4 plate is acceptable CHASSIS CHANGES CHASSIS MODIFICATIONS TO ENHANCE TURBOCHARGER 172 CHASSIS CHANGES Several changes to the F-series pick up truck have been made to enhance the turbocharger package. ‘These include: * Slotted front bumper * Engine cooling fan clutch Air dam below radiator © Micro processor for £400 * Re-configured dipstick for E40 * Low restriction exhaust 65CHASSIS CHANGES BUMPER SLOTS The three slots added to the front bumper provides increased air flow for engine cooling, RADIATOR ENGINE COMPARTMENT 174 E40D DIPSTICK The E40D transmission dipstick and tube has been reconfigured to provide exhaust clearance. The new tube is supported at the engine by a stud used to secure the right valve cover. 66 AIR DAM An air dam, attached to the radiator lower support, provides better air movement through the radiator and engine compartment 175CHASSIS CHANGES E40D TRANSMISSION Meters le sss aor Ue} Were ese ee] Ste nc eG omer eh 176 EXHAUST SYSTEM To enhance the engine's air flow capability, a low restriction exhaust system has been utilized. * The system is designed to operate with a 2" Hg-3" Hg (4-6 ps)) of back pressure COOLING FAN CLUTCH Peper een a Cag Oka b} Bsn) Deel E40D MICROPROCESSOR The microprocessor controlling the E40D has been re-calibrated to provide durability in t turbocharger application EXHAUST FLOW Me Sencha ya BTW ea Cag FAN CLUTCH ‘The engine’s fan clutch has been redesigned to increase fan speed at all engine rpm to enhance engine cooling 67SOSTOMER WANE re Aging naw ASL gemeent Bane. semvee bRoceVEAT VERCLERERACS REE TERT TRCECTION ORF SERTA ooowereR REM NUTT Saree: | os = nr poem een 2 fecmmae Tea eee RUSTOUER concen” (LEME CoTCOCTNO NTS coy) + emetic ant teas tn fc tera Eat Se oe TESTS Tests Tests Tere RES TNERTE SPECIES ALTERS TSG _AN-WiTT TSTRUMENT __GuDaNE OAT GER . GHEGK FUEL RETURN LWNE PRESSURE — Se Raman 73. CHECK TNUEGTION UNES AND JECTION NOZLES TeatemeSon Wm NEUTAN ARR AAD REAR HMEES OFF TE CAD Tae. | ark ‘mate ichsan noms Se [beer Pu Hose || epsarpace SERA SOR TESTES TS MOTE] (| NOTE: PERFOMW Ont ENGINE 1 MISS OR RUNNING ROUGHLY. 1. EXTERNAL LEAKAGE — See lsrafon—Aovess See © Feet Recor eeaton of aks fniucraon Revers Sie ao Gamsie Oi Waer Record cation of aks in “Comments INSTRUMENT 1ST CHECK, 2ND CHECK ‘eval hook 2. ACCELERATOR UNKAGE — Seo listaton— Rovere See sis ver conics Wop ail peal cepression INSTRUMENT 1ST CHECK, eND CHECK A + Few arexten OF and estes no pretent— GoTo oH SS ‘Row drecion OK and butbesprosent— goto Fuel Syslom Disgnoste Procedre (soe CarTux Emssen Diagnosis Stop Meal, Vere Hand reum to test 8 whi ia ¢ doommbwe + Flom drecion NOT OK — Repice continuous ven assembly. Gof test 6. om "FUEL_CONTAMINATION. ‘Oban ae sare ae visual examine te saree of uel na lear container {ineucing bottom of conlaner) for parilos, clousing_ er other iqud Contamination such as water. Samba mus be tan ae FuolPeimina Vent ‘Sizvadacvatvelonihe met nese INSTRUMENT (Clear Consinee rw sontamnation fe feurd-— go SAT. {Eeeetamnaton steura replace hte ara clean or epar chasse ftom Goro test 7 Heck [elu ine ermoved lel GA msl be reconnected > [Mosse of 9000 RPM wi scsossoves unod of Reso Vaue Below — INSTRUMENT —GUDELNEDATA = 1STCHECK @ND CHECK & +045 PsiGauge ‘som | fom | Some | Pai, and 5663 Adapter AIR INTAKE RESTRICTION — Soo saton— Fvewe Ste Teasare a 6000 AP wih acomsorc wrbed a ecard Vale” Below ‘eget are eaticion gauge (iter Mince, Opera angina at 000 em. THE icon is measuredremove iter minder and sia O14-0076% tos ‘magnanete gauge and est restcion INSTRUMENT. GUIDELINE DATA oveo07e Test Kt ISTOHECK 2No CHECK ‘Check inlecton ines for Kras andor vesvtions. Remove nozzles and tes peng possure and ip lskage on each nose No coe evaluation shoud be perormed, GRUTION: Koop nance and otha pans of the body away fom the spraying hove, The lquc eecharge lavee tho nozzlo ip wih suiciont force To Danette the shin and cause sofcus inky. To nozzle ip shouldbe sounded bya rangparererocopace aval pening Pressure ard Tp Leakage 1 Cofnect nozl to nozzo teste, “10 tas onsale teay_tueldschane tin. Pump tester omy ‘ng tooo highest persue teaches py to the noe opaning (> Charging hi) ans recordin Box Ablow “Ensue aL nozze body and ip ae compe cy beloe sarin at, (porate eto monn posse fr 9 soonds at 200 PSL bolow fozzle jpeeur recordin A for each nozzle, Nozzo pcan bo wel nS seconds Ertmoptt aout na INSTRUMENT GUIDELINE DATA TEXHAUST SYSTEM CONDITION Rapa Tr GRE FRE WH COU CRIES 8 TSAO, REO SEE -Gomment NSTRONENT CECE ‘Visual Check Gere ane “@. TURBOCHARGER BOOST — Sw lunalor— Aiwa Sie Remove ak cleaner assemoy and connec 0-15 ps presure gauge othe boost tego on oar chanerRe-ttalo a cane ‘ith automat ranambson, perform atorqe converter alte (180 2100) spn Observe PS. roming ‘witha vans n 2 gear acceler from 1200 to 2800 mm ‘Observe PS reedng INSTRUMENT GUIDELINE DATA ISTCHECK__2NDOHEOK 0-15 ps Gave 1 NOTE: IF BOOST IS WITHIN. LIMITS PERFORMANCE 18 ACCEPTABLE + Woosts on. goto 55. ‘5. WASTEGATE ACTUATOR CONDITION — Sv lstaibo—Ans Sat ‘Connoct 020 psi gauge ar hang pump o actuator. Appy pressure to actuator \wth hand pump, Actuator re shod beg o move at 1215p. Full atatr ros Travel shoud occur at 20:22 ps. Observe pressure gauge fr 90 seconds fer 420.22 painas been aanea No decrease poste suas ooo INSTRUMENT BUIDELINE DATA ISTCHECK aND CHECK. 0.90 PSI GAUGE. Tar 63a reve, erovs ras rom wastoale 37d ha WARTS wastegate is foe, rpc acuta: rast wre ot op wat or ep.08 Hus cotaing 7 FUEL SUPPLY SYSTEM — Sco Raton — ore Soe Til minder Inoaiosrplacarantnecess4, oFGce and let I steve 30 pace Mer element aha retest tess than "inspect orlaks Fer sstom. Train gueines, got tot 10, 614.00300 Injection ze Teter rox FUEL SORE RecarT TS Below Tass 213000 RP wih aoossones re INSTRUMENT CUDELNE DAA. IGTCHECK __eNO.GHECK [eas recuse or eee ee | Soest aaa + Tpeseae reat gue, go 188 76 Nrensie low, got est 78. ‘ee aon — Ree Sie (0. LOW IDLE (RPM) — [A Manca vansmison eal postion” B._Avloratewanemation arve poston” INSTRUMENT GUIDELINE DATA ISTCHECK 2ND CHECK A 078-00200 Omana Teng — SRISETS ctor anc 076-0020" Adaptor liga Record vate" Below FUEL SUPPLY PUMP OUTLET PRESSURE — Record "valu Remove Fal ining Vont (Strader vate) and neal gauge. Measure a 75 APH wih accesories ned of. INSTRUMENT GUDELINE DATA 0-15 PSI Gouge snd 2019 Aer $sTCHEOK. iEOK A TT,_INJECTION PUMP TIMING — Se usralan— vars San ‘tach the clare othe Ine prosure sensor onthe No. tection nazze fr ‘Series, and connect the ayrame tering moter. Dil -20" lsat on the meter. Dieconneat cold stat acvance eolenas canneter am he slenad tormna Manaln 2000 RPM wih engine at operating temperature and record dynamic tering in Box A. Apply batloryweige te solo Tormnal, main 2000 FEM land record eyrame tnngin Box 8 (Recor "Values" Blow) Ome (A Openeg Press FST [ste Leacge ox OK) + it nozzle f rot To speceaion replace nozzle assembly NOTE: WARRANTY CLAING FOR REPLACEMENT OF THE NOZZLES) WILLNOT BE ACCEPTED UNLESS THE COMPLETED ENGINE PERFORMANCE CHART (VALUES RECORDED) 1S SUBMITTED WITH THE RETURNED PARTI) 74. CRANKCASE PRESSURE — Se istaton—Ravese See [weasure pressure at of pipe Loosen eranicase Gepresson regulator (CDF lane, inert een carszoars bebwosn COR valva and seal tg, Retgln COR land ine cipsek is eae in ite, Remove areboars upon coreleton oft TWeasure a S000 API wih abasoroe Umeda. Roesrd Value Below INSTRUMENT pus 014-00749 ses1 Aaacets GUIDELINE DATA 187 GHEOK GHD CHECK a| + Tpressure meets guideline, replace fuel fiter and repeat test 7A. INSTRUMENT GUIDELINE DATA, 1STCHECK 2ND CHECK 1 tpecsus etn gotten 70 378-00200 @ save easter 951 fom et TA nied bt copped oman neo FUEL PUMP CAPACITY ~~ — Record Volume In 30 ee bre ter i Mesure a 75 RPM wi acessories red of «vanes Ting Check (| shou be 1” (rn) ve aaress an Ting INSTRUMENT “GUDELNEDAA™ISTCHECK__2ND CHECK A CoN eae =e Tt [oe A teeitan 10% advarea tom A repoce a con pane entire orc Ra Ta CHECK INJECTION PUMP TRANSFER PRESSURE — Ste Acoper Soe lainn fee Sc + Pressure aa volume meet guideline — go 0 18 1 Preeute OK andvoue NOT OK ~ goto tet 7D. {elume OX and presute NOT OK — fplace fel supply pump and vepest + Pressure ana vole NOT OX — goto ts 7. MOTE: PERFORM ONLY IF 1ST TIMING CHECK (STEP 11) WAS NOT WITHIN’ SPECIFICATION, SAFETY PRECAUTION THE COMPRESSOR INLET SAFETY GUARD MUST BE INSTALLED WHEN ENGINE IS RUNNING WITHOUT AIR (CLEANER ATTACHED. 1D, CHECK RESTRICTION AT SUPPLY PUNP INLET — uel tet conthous ver. Run engne at 3000 RPM for 2rarutes ana odeome ‘ear el hora for tltas il wih ong at 9000 RPM. Ful ould bo foe bubbles wihin 2 mevies. Correct Wal low dvocton i rm the Wet liter Towards the tuo vue systm (rvecon norzes) Fuel flow in th opposte ‘Srocton isles an repeativ check alm fn vere ting shi ested fl supply sytem, ‘jlue" Below. ‘CHECK FOR FUEL QUALITY — See inaton— fines Sue ‘estar a 2000 APY wi ascossoree ued a INSTRUMENT GUDELINE DATA” ISTCHECK Insalen epropriate eat of car PYC hose nace ofthe nutter tose.on ine | *[ 930 9. ‘x | Vaouam Gage > [Hesse a 9000 RPM win sccatcovis winad cL Record Value" Boon] INSTRUMENT GUDELINE DATA IST CHECK 2ND CHECK & + lfprossure is nolo specteaten, thoi an elomal angie canoer «IF THE PERFORMANCE CONCERN STILL” EXISTS. AFTER COM: PLETION OF THE ENGNE PERFORMANCE CHART REPLACE THE INJEC ‘TON PUMP. NOTE: WARRANTY CLAMS FOR THE INJECTION PUMP WILL NOT BE ACCEPTED UNLESS ALL TAMPER RESISTANT SEALS. AREINTACT NO THE COMPLETED ENGINE PERFORMANCE CHART (VALUES RECORDED) IS SUBMITTED WITH THE RETURNED PART. EVALUATING NORMAL EXHAUST SMOKE sont pace teed vgn sag eles a en “ts ots ean tm ata he gra wa pemitecaceclars tne eva «+ [sar 2000. TED PS aoe 5es0 caper and S632 Adzot + TES hae yor — rep rrcionn Uae layer an + [TMi ees tan 6 n-Hg. — replace tel supply pump and rept test 7A + pressures net o speciation, replace ue rection pure, NOTE: WARRANTY CAMS FORTHE MUECTION PUMP. WIL NOT 6 [ACCEPTED UNLESS ALL TAMPER RESISTANT SEALS ARE INTACT AD HE. COMPLETED ENGINE PERFORMANDE CHART (VALUES FE CORDED) 1S SUBMITTED WITH THE RETURNED PART. PREVOUS EOMONS WOST NOT BE USEDSETUP ILLUSTRATION OF ROTUNDA™ 014-00761 connect cteak PRESSURE TEST KIT AND TEST FITTINGS PVC TEST HOSE AT ) REMOVE SCREW FROM. ‘TRANSFER PUMP PRESSURE PORT, INSTALL TOOL, THROUGH LOCK AND ‘O-RING PORT. LEVER ACCELERATOR LINKAGE TEST 2 AND 10 INJECTION 014.0300 NozzLe NozzLE TESTER, LEAK-OFF | ReMoveo INJECTION PUMP FUEL CHECK FUEL FILTER TRANSFER PRESSURE ‘OUTLET PRESSURE TEST 7A, AIR INTAKE RESTRICTION TESTO LOOSEN CDR FASTENERS sINSERT CLEAN CARDBOARD BETWEEN CDR VALVE AND SEAL RING ‘RETIGHTEN COR FASTENERS ‘ REMOVE FUEL PRIMING VENT USE OT6-208629 CALIBRATING OIL ONLY. ‘TEST INJECTION NOZZLES TEST 13 078.00201 LINE PRESSURE ADAPTER i FUEL RETURN LINE PRESSURE TESTS ‘SUPPLY PUMP OUTLET PRESSURE & CAPACITY TEST 7B & C T0045 Pst PRESSURE PUMP TEST 7D REAR VIEW T0015 6s! PRESSURE n Tor view BOTTOM VIEW EXTERNAL FUEL LEAKAGE TEST 1 (078-00200 DYNAMIC TIMING METER F SERIES SENSOR LOCATION -RODUCTION TIMING MARKS AT ‘THE 10:00 O'CLOCK POSTION (AS VIEWED FROM THE DRIVER'S POSITION) RESTRICTION AT SUPPLY TURBOCHARGER BOOST WASTEGATE ACTUATOR DYNAMIC TIMING MARK LOCATION IN TEST 4 TESTS TEST 11 MAGNETIC PICK-UP DYNAMIC TIMING SPEC. 8° +2° BTDC @ 2000 RPM ENGINE TIMING SPECIFICATION TEST 11