Serv. Infor. N.

2004/0057/1

Stampa Chiudi

Service Information 2004/0057/1

01 PRODUCT IMPROVEMENTS
EUROTECH, EUROSTAR, EUROTRAKKER, STRALIS
54.24.10
TURBO CHARGER

Subject
Procedure for cleaning the turbocharger to restore performance - Vehicles with CURSOR 8/10/13 engine

Description
Use this procedure if performance is reduced and it is diagnosed that the mechanism
for the variable geometry cannot move freely.

Vehicles affected
Stralis / EuroTech / EuroStar / EuroTrakker.
Dealer action
See "Procedure"

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This Service Information is circulated for notification purposes only.

Receipt of this information does not give the right to modify vehicles as a precaution.

Procedure
1.0 Cleaning the actuator sleeve

1.1 Before the turbocharger can be removed

from the engine, first disconnect the actuator
only by removing the three bolts securing it to
the central turbocharger housing.

Visually check the condition of the actuator

pin and sleeve and in every case clean both
parts as shown in the following illustrations.
Do not use any abrasive medium. Use non
scouring, microfibre cloth (type Scotchbrite by
3M).
Before cleaning: see photo.

Cleaning the pin

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After cleaning

Cleaning the actuator.

Grease the sleeve and the pin exclusively with
grease type CASTROL LM GREASE, lithium
based.

1.2 Check the correct operation of only the

actuator by applying compressed air. Vary the
pressure evenly with a pressure regulator
between 0 and 3,5 - 4,5 bar. The actuator must
move proportionately without hesitation.
If this is not the case, replace only the
actuator.

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1.3 Check, with air applied at a pressure of 3

bar, if the actuator shows any signs of leakage.
If necessary, use soap suds. If there are any
leaks, replace the actuator
with a new one from the parts department.
1.4 Check the variable geometry mechanism
movement manually. Move the actuating rod
backwards and forwards and check that there
is absolutely no hesitation.
If there is no hesitation, the turbocharger need
not be opened for cleaning. Fit the actuator
and tighten the three bolts to a torque setting
of 25 Nm.
After the actuator has been fitted, check the
value of the maximum actuator stroke as
follows.
1.5 Vary the air pressure between 0 and 3,5 -
4,5 bar and with sliding calipers measure the
actuator stroke. The correct values are shown
below. Use sliding calipers.
HY40V 8,5 mm +/- 0,5 mm
HX55V MkII 11,5 mm +/- 0,5 mm
HY55V 11,5 mm +/- 0,5 mm
Check the variable geometry mechanism
movement manually. If there is any hesitation
the turbocharger must be removed from the
engine in order to carry out the internal
cleaning procedure as described below.

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2.0 Removing the turbine housing.

2.1 Mark the turbine housing, the V strap (metal

clamping strap) and the central housing.

2.2 Remove the lock nut from the V strap. Use a

release oil spray to prevent the V strap nut
sticking.

2.3 Open the V strap with suitable pliers and turn

it simultaneously around the central housing to
release.

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2.4 In order to relocate the turbine housing on the

central housing correctly, use a drift to apply a
mark on the connection of both housings.

2.5 Remove the turbine housing. If the turbine

housing is difficult to remove from the central
housing, use a hide or soft metal hammer (e.g.
copper). Tap on two opposite points (180°
removed) on the turbine housing and prevent the
turbine housing from falling, otherwise the fan or
VGT mechanism may suffer damage.

IMPORTANT:
AFTER THE TURBINE HOUSING HAS BEEN
REMOVED, THE VGT MECHANISM MUST
BE FAR EASIER TO MOVE THAN DURING
THE PREVIOUS TEST. IF THIS IS NOT THE
CASE, STOP THE PROCEDURE AND
REPLACE THE TURBOCHARGER.

3.0 Checks and cleaning

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3.1 Check if the turbine housing split ring can

move freely.
NOTE: If there are heavy carbon deposits and
the ring is difficult to move, the turbine housing
must be cleaned internally in the area around
the ring. NOTE: If the ring cannot move freely,
even after cleaning, stop the procedure.

NOTE: There may be small cracks visible

between the splits and the internal diameter of
the ring. These are acceptable and have no
influence upon turbocharger performance.

3.2 Visually check the fan and the VGT

mechanism for traces of damage, such as
deformation, fractures and bent blades.

If one or more of these problems present

themselves, replace the turbocharger: see next
illustration.

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Presence of carbon deposits, hindering the

rotation of the fan.
Replace the fan.

VGT mechanism damaged.

Replace the fan.

NOTE: The turbocharger must be protected so

that no debris can enter the internal
mechanism.

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3.3 Clean the three turbine housing surfaces

(shown by the red arrows in the illustration
below) with a scraper and / or emery cloth
(P180). A rotary steel brush may also be used.
Take care to remove only corrosion and not to
damage the surfaces.

Surfaces to be cleaned.

3.4 Remove the exterior sealing ring.

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3.5 Clean the three corresponding surfaces of

the central housing (shown by the red arrows in
the illustration below) with a scraper and / or
emery cloth (P180). A rotary steel brush may
also be used. Take care to remove only
corrosion and not to damage the surfaces.
NOTE: Ensure that when cleaning the three
central housing surfaces that no variable
geometry ring material is removed.

Surfaces to be cleaned.

3.6 Clean the external sealing ring with emery

cloth. If this ring is damaged, it must be
replaced with a new ring from the parts
department (F2B engines: part No. 42546379,
F3A/ F3B engines: part No. 42546381); see
Parts information.

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3.7 Blow clean the renovated surfaces with

compressed air. Blow compressed air through
the openings in the variable geometry ring to
remove any debris remains from the interior of
the ring.
3.8 Fit the external sealing ring and ensure that
it is correctly seated on the central housing.

4.0 After cleaning, check the VGT mechanism.

4.1 Using a pressure regulator apply compressed air at a pressure of 3,5 bar (max. 4,5 bar) and
check that the actuator can be moved.

4.2 Vary the pressure between 0 and

3,5 - 4,5 bar and with sliding calipers measure
the actuator stroke. The correct values are
shown below.

HY40V 8,5 mm +/- 0,5 mm

HX55V MKII 11,5 mm +/- 0,5 mm
HY55V 11,5 mm +/- 0,5 mm

5.0 Fitting the turbine housing.

5.1 Lay the turbocharger in a vertical position

at its compressor side.

5.2 Refit the V strap. If the V strap was

damaged or deformed during removal, it must
be replaced by a new one from the parts
department (part No. 42546380, for all
engines); see Parts information.
If a V strap with integrated heat shield is
replaced, also replace the actuator with one of
the latest version, i.e. with integrated heat
shield (part No. 42541469, for all engines); see

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Parts information.

5.3 Apply a thin layer of "Antiseize" paste to

the renovated surfaces of the turbine housing
and the central housing.

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5.4 When fitting the turbine housing ensure

that the fan and VGT mechanism are not
damaged. It is possible for the VGT mechanism
not to align directly with the turbine housing
split ring. Under no circumstances apply excess
force when fitting which could cause damage to
the VGT mechanism and incorrect functioning
of the control system.

5.5 Check, once the turbine housing is fitted, that the turbine housing and central housing surfaces
are located correctly relative to each other.

5.6 Align the turbine housing, the central housing and the V strap conforming with points 1.1 and 1.3.

5.7 Secure the V strap to a torque setting of 11,3 Nm.

6.0 Check the VGT mechanism after fitting.

6.1 Using a pressure regulator apply a pressure of 3,5 bar (max. 4,5 bar) and check that the actuator
can be moved.

6.2 Vary the air pressure between 0 and 3,5 - 4,5 bar and with sliding calipers measure the actuator stroke.
The correct values are shown below:
HY40V 8,5 mm +/- 0,5 mm
HX55V MKII 11,5 mm +/- 0,5 mm
HY55V 11,5 mm +/- 0,5 mm

Parts

Ref. model / Old number Qty Description New number Qty

version
Cursor 8, F2B Sealing washer 42546379 1
engine
Cursor 10/ 13, Sealing washer 42546381 1
F3A/ F3B engine
Cursor 8/ 10/ 13, V strap 42546380 1
F2B/ F3A/ F3B
engine

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Cursor 8/ 10/ 13, VGT mechanism 42541469 1

F2B/ F3A/ F3B
engine

Administrative information

Ref. model Code description Code Labour time [W.

U.]
Cursor 8 / 13 Replacing / overhauling turbocharger 542410116 17
turbocharger
Cursor 10 Replacing / overhauling turbocharger 542410116 22
turbocharger
Cursor 8 / 10 / 13 Internal cleaning turbocharger and 542410502 10
turbocharger checking VGT
Cursor 8 / 10 / 13 Preparing MODUS station 295101102 2
turbocharger
Cursor 8 / 10 / 13 Diagnosis engine EDC system 295167104 4
turbocharger
Cursor 8 / 10 / 13 Preparing MODUS station 295301102 1
turbocharger
Cursor 8 / 10 / 13 Diagnosis engine EDC system 295367104 4
turbocharger

Product Quality
09/09/2004
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