0384068 JOHNSON COVER ASSEMBLY

Introduction
Do not perform any procedure that is outlined in this publication until you read and understand the information that is contained in this document.Required Parts
Use the 215-2592 Kit (Wastegate) in order to calibrate the new turbocharger wastegate actuator kit properly.Illustration 1 shows the 215-2592 Kit (Wastegate). However, the 213-4269 Adapter As (Crimping) is not shown in Illustration 1.
Illustration 1 g01580494
(1) Air pressure regulator (2) Air pressure gauge (3) Two 4P-5866 Clamps (4) A tee or a cross (5) A test hose (6) A hose barb coupler (7) An air valve (8) Valve (9) A fitting that is used to make a connection to the air supplyNote: The air pressure gauge must have a minimum pressure rating of 207 kPa (30 psi). The gauge must also have graduations of 1.72 kPa (0.25 psi).Note: Test hose (5) must have a 6.35 mm (0.25 inch) inside diameter to will allow the test hose to connect to the wastegate actuator properly.You will also need a dial indicator with a base that can be attached to the engine.A new 317-5277 Turbine Housing As and 384-1864 Actuator Kit , or 439-1316 Turbocharger Actuator Kit will be needed after failure.Note: The 439-1316 Turbocharger Actuator Kit is utilized for machines that have repeated actuator malfunctions and/or diaphragm failures.Determining the Actuation Calibration Reading
Illustration 2 g02725982
Allow the turbocharger to cool.
Install dial indicator (1) on the engine. The travel of the dial indicator must align with the travel of the rod (4) or an error in the measurement will occur. Refer to Illustration 2.
Remove the hose (2) from the actuator (3) .
Illustration 3 g02726187
Connect the air supply to the air pressure regulator (9) .
Set the air pressure regulator (9) to 0 kPa (0 psi).
Connect the test hose (7) to the actuator (3) with hose clamps (8) .
Turn the knob on the air pressure regulator (9) and slowly increase the air pressure while you observe the dial indicator (1). Increase the air pressure until the travel of the rod (2) is 1 mm (0.039 inch)1.00 mm. Observe the pressure gauge (6) and record the pressure reading.
Turn the knob on the air regulator (1) and slowly decrease the pressure to 0 kPa (0 psi). Repeat Step 7. Observe the pressure gauge (6) and record the pressure reading.
This pressure reading is the Actuator Calibration Reading. Adjust the calibration to 128 3 kPa (18.6 0.5 psi). Use the following procedure to adjust the calibration. Each rotation of the rod end is a change of 3.4 kPa (0.5 psi)
In order to increase the calibration setting, increase the preload on the actuator spring by screwing the rod end further toward the canister. Each half turn is an increase of 3.4 kPa (0.5 psi).
In order to decrease the calibration setting, decrease the preload on the actuator spring by unscrewing the rod end further away from the canister. Each half turn is a decrease of 3.4 kPa (0.5 psi).
Repeat Step 2 through Step 9until the calibration meets the prescribed setting 128 3 kPa (18.6 0.5 psi).