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NUMBER: 2 109 REV

2009

S.M. REF.: Listed in Table 1

ENGINE: EPA04 Series 60

DATE: June

SUBJECT: TURBOCHARGER ACTUATOR ADJUSTMENT


ADDITIONS, REVISIONS, OR UPDATES
Publication Number

DDC-SVC-MAN-0004

Platform

EPA04 Series 60

Section Title

6.5.3.2

Change
An adjustment routine
on how to measure and
adjust the turbocharger
actuator on EPA04
turbochargers has been
added.

Page Number(s)

634

NOTE: Page numbers are based on the most recent version of the individual publication and may be adjusted throughout the annual print cycle.

Table 1

Effectivity Table

TURBOCHARGER ACTUATOR ADJUSTMENT

Check the turbocharger actuator calibration as follows:


NOTICE:
To be able to perform the turbocharger actuator adjustment;
Engine Serial Number 06R1999999 needs to be in the ECM
running the engine. This can be done by having your test ECM
(23533662) programmed with this Engine Serial Number or by
re-flashing the original ECM.
NOTE:
If the original ECM is going to be re-flashed it is important to write down or print the accumulators,
injector codes, and parameters so they can be re-entered when original calibration is re-flashed.
When using the test calibration there will be fault code(s) present. Disregard them as they will
not affect the outcome of the test. Once the original calibration is installed back into the ECM,
the codes should be cleared.

1. Run the engine allowing the engine coolant to reach operating temperature, 88-96C
(190-210F).
2. Turn engine off.
3. When testing or adjusting turbocharger actuator, perform step a or b:
[a]

Install test ECM 23533662 with Engine Serial Number 06R1999999. Continue to step 4.

NOTE:
When reflashing the original ECM, select No Charge, then from the drop-down box select
Description and for the reason Turbocharger actuator adjustment. If the original ECM was
reflashed, all the customer passwords, accumulators, injector codes, and parameters will be reset to
default and will need to be reset using Diagnostic Link.

[b]

Re-flash ECM on the truck with Engine Serial Number 06R1999999. Continue to step 4.

4. Remove air inlet tube going to the turbocharger and install protective shield J-26554-A. Verify
the charge air inlet temperature sensor is connected.
5. Start the engine.
6. Connect Diagnostic Link. Verify version of Diagnostic Link is 6.5 or newer.
7. Close the Welcome window and Engine configuration window.
8. Open Diagnostics pull-down menu.
9. From the drop-down menu, open Turbocharger Actuator Service Procedure.
10. Acknowledge caution, click to agree. Click Next.
11. Verify that the air inlet tube is removed from the turbocharger and the protective shield
(J-26554-A) is installed on the turbocharger inlet. Click to agree.
12. If the truck is running, the box will be checked for engine started. If not, start the engine. Verify
that the climate control (Defroster and Air conditioning) is off. Click to agree.

NOTE:
If the engine is not at the required operating temperature for the test to run, a progress window
will appear. Once the engine reaches the required temperature the progress window will close
and the test will begin.
NOTE:
There is a five minute turbo cool down period every time the engine RPMs increase. During the
five minute cool down, do not increase the RPMs by pressing on the accelerator. If this happens,
the five minute timer will reset. After the five minute cool down is complete, if the start button was
clicked, the test will automatically start (engine RPMs will increase).

13. Click start to begin the routine.


NOTE:
If the turbo reaches a speed of 75,000 RPM the test will abort and a window will appear stating
"Aborted due to turbo overspeed. You can view the turbo speed on the right hand side of the
screen in the Instruments window. If the turbo speed is over 75K and the pressure ratio is over 2.0,
shorten the actuator rod by 6 turns and retest. If turbo still over speeds, replace the actuator and
retest. If the turbo speed is over 75K and the ratio is under 2.0, verify air induction system for
leaks. Further information can be found in DDC-SVC-MAN-0012 (Restricted or Cracked Charge Air
Cooler or Leaking Intake Manifold).

Figure 1

Instrument Window

14. Once the test (measuring) is over (engine back to idle), click the Next button.
NOTE:
To help see the number of turns on the actuator rod, mark the adjuster rod with a paint mark. Verify
that both lock nuts are loose and that the adjuster turns freely on both shafts. If the adjuster is frozen,
replace the actuator. If not replaced, you will have a difficult time adjusting the actuator.
NOTE:
Both lock nuts are right-handed threads.

15. Adjust the turbo actuator rod the estimated number of turns shown on the screen. Clockwise
will lengthen the rod and counterclockwise will shorten the rod.

Figure 2

Actuator Rod

16. Repeat measurement using Diagnostic Link; click the Repeat Measurement button. Verify
that the adjustment is correct. If not, re-adjust the actuator rod and retest.
NOTE:
If the turbo will not adjust and/or pass the test after five attempts, generate a service code by clicking
on the Generate Service Code button. Record the service code and replace the actuator assembly.

17. Once the adjustment is complete (test passed), a service code will be generated. Record the
service code.
18. Remove test ECM or re-flash the original ECM back to the original Engine Serial number.
19. If re-flashing the ECM, enter all the accumulators, injector calibration codes and customer
preferences.
20. Verify the repair.

ADDITIONAL SERVICE INFORMATION

Additional service information is available in Power Service Literature.

Detroit Diesel, DDC, Series 60 and the spinning arrows design are registered trademarks of Detroit Diesel Corporation.
Copyright 2009 Detroit Diesel Corporation. All rights reserved. Printed in U.S.A.