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Detroit Diesel — Wastegate Actuator Installation and Adjustment

A Detroit Diesel service procedure — check it applies to your exact model before use.

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Before you start

  • Proper installation and adjustment of the wastegate actuator requires the use of a highly accurate digital air pressure gauge, TLZ00101 (included in special tool kit TLZ00100) or equivalent.
  • If during the adjustment, the pressure is exceeded, reduce the regulator output to 0 (zero) psi and increase slowly again to 25.5 psi (175 kPa).
  • It is critical that the swing-arm remains in the closed position and the actuator rod is not moved in or out of the actuator during the adjustment. If the rod is moved in or out, it will slowly return to the correct position and must be readjusted.

Procedure

  1. With the adjusting rod and jam nut removed from the actuator rod, install the heat shield on the new wastegate actuator, and then install the wastegate actuator to the actuator bracket. Tighten nuts to 12 N·m (9 lb·ft).
  2. Thread the jam nut and adjusting rod onto the actuator rod; do not tighten.
  3. Attach regulated shop air to the digital pressure/regulator setup.
  4. Adjust the regulator output knob until airflow stops.
  5. Turn the digital pressure gauge (TLZ00101 or equivalent) on and set to zero.
  6. Attach the digital pressure/regulator hose to the wastegate actuator port.
  7. Connect the new wastegate actuator to a regulated air supply. Secure all air hose connections, ensuring there are no leaks.
  8. SLOWLY adjust the air regulator output to 25.5 psi (175 kPa).
  9. With the wastegate in the fully closed position, adjust the free length of the adjusting rod by rotating it, so that the adjusting rod hole lines up with the wastegate swing-arm pin.
  10. Install the adjusting rod on the wastegate swing-arm pin. With the wastegate swing-arm in the fully closed position and the adjusting rod length properly set, the adjusting rod should be perfectly aligned with the swing-arm pin.
  11. Install replacement E-clip onto the wastegate lever pin.
  12. Tighten the jam nut on the wastegate actuator adjusting rod, taking care not to rotate the actuator shaft. Torque jam nut to 5 N·m (4 lb·ft).
  13. Disconnect regulated air supply.
  14. Install the turbocharger. Refer to section 6.7.3.
  15. Verify the repair.

Tools required

  • torque wrench
  • regulated shop air setup
  • digital air pressure gauge TLZ00101

Specs & torque values

  • Actuator nuts torque: 12 N·m (9 lb·ft)
  • Jam nut torque: 5 N·m (4 lb·ft)
  • Wastegate actuator calibration pressure: 25.5 psi (175 kPa)

Source: manual:609-09 - EPA07 MBE 4000 TURBOCHARGER ACTUATOR (WASTEGATE) REPLACEMENT.pdf. Figures and steps are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.