0328598 JOHNSON EXHAUST HOUSING, Outer

Table 1
Required Tooling For C9.3 Applications    
Quantity     Part Number    
1     215-2592 Wastegate Kit    
1     5P-8869 9/16"-18 JIC to 1/4"-18 NPTF    
1     006-6586 1/4"-18 NPTF to hose barb    
Table 2
Required Tooling For C13, C15 and C18 Applications    
Quantity     Part Number    
1     215-2592 Wastegate Kit    
1     061-7921 7/16"-20 JIC to 1/4" NPTF    
1     006-6586 1/4"-18 NPTF to hose barb    
Illustration 1 g02032893
(1) Connection points to checkComplete the procedure in the order in which the steps are listed.
Table 3
Troubleshooting Test Steps    Values    Results    
1. Inspect the Air Lines from the Exhaust Balance Valve Solenoid to the Exhaust Balance Valve Actuator
Inspection of the air lines is difficult in some applications. Test Step 5 will provide further testing procedures.
A. Inspect the air lines from the outlet of the exhaust balance valve solenoid to the inlet of the exhaust balance valve actuator. Inspect the lines for any signs of leakage.
   
Damaged Air Line    
Result: A line is damaged.
Repair: Repair the line or replace the line. Return the unit to service.
Result: A line is not damaged.
Proceed to Test Step 2.
   
Illustration 2 g02032979
(2) Linkage to the exhaust balance valve (3) Connection point from the exhaust balance valve to the linkage, soot build -up at this linkage is normal
Table 4
Troubleshooting Test Steps    Values    Results    
2. Inspect the Linkage to the Exhaust Balance Valve
A. Inspect the linkage to the exhaust balance valve from the canister to the housing. Also, inspect the connection point from the linkage to the valve. Inspect the linkage for the following issues:
1. Bending
2. Breakage
   
Damaged or Broken Linkage    
Result: The linkage is damaged.
Repair: Replace the turbocharger. Return the unit to service.
Result: The linkage is not damaged.
Proceed to Test Step 3.
   
Illustration 3 g02337917
(4) Pressure regulator on the 215-2592 Wastegate Kit (5) Gate valve # 1 on the 215-2592 Wastegate Kit (6) Pressure gauge on the 215-2592 Wastegate Kit (7) Hose from the mixer to the exhaust balance valve solenoid (8) Exhaust balance valve solenoid (9) Exhaust balance valve (10) Gate valve # 2 on the 215-2592 Wastegate Kit
Illustration 4 g02402325
(7) HoseOnly disconnect the hose from the mixer, do not disconnect the hose from the balance valve solenoid.
Illustration 5 g02402320
(5) Gate valve #1 (10) Gate valve #2
Illustration 6 g02338036
(11) Fitting for the line to the exhaust balance valve
Table 5
Troubleshooting Test Steps    Values    Results    
3. Test the Exhaust Balance Valve Solenoid to Make Sure that the Valve Is Not Stuck in the Closed Position
A. Disconnect hose (7) from the mixer. Refer to Illustration 4.
B. Connect the 215-2592 Wastegate Kit and necessary adapters between hose (7) and the mixer. The other end of hose (7) must stay connected to the inlet of the balance valve solenoid.
C. Turn the keyswitch to the OFF position.
Only apply 138 kPa (20 psi) air pressure to the exhaust balance valve.
D. With gate valve (5) in the open position, regulate the supply air pressure to
138 kPa (20 psi). Make sure gate valve (10) is closed. Once the pressure is stable, close gate valve (5) .
E. Loosen fitting (11) for the line from the exhaust balance valve solenoid to the exhaust balance valve.
   
Valve Stuck Closed    
Result: Air leaked out of the line from the exhaust balance valve solenoid after the fitting was loosened.
The solenoid is not stuck closed. Proceed to Test Step 4.
Result: Air did not leak out of the line from the exhaust balance valve solenoid after the fitting was loosened.
Repair: The exhaust balance valve solenoid is not o