DD15 Defective Turbocharger

Check as follows:‪

1. Remove the charge air cooler inlet duct connected between the turbocharger and charge air cooler.
2. Visually inspect the charge air cooler outlet duct.
   1. If excessive engine lube oil is present, go to the next step.
   2. If no engine lube oil is present, check for worn or damaged valve or cylinder kit, refer to “7.2 Worn or Damaged Valve Guide/Seal or Cylinder Kit” .
3. Replace the defective turbocharger. Refer to “4.2 Turbocharger” in the “Air Intake System” chapter of the EPA07 DD15 Workshop Manual (DDC-SVC-MAN-0002).
   1. Remove defective turbocharger from the engine.
   2. Tag removed turbocharger for remanufacture.
   3. Install a replacement turbocharger.
      

      ENGINE EXHAUST ‪
      To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area. Engine exhaust is toxic.‪

4. Start and run the engine.
5. Run the engine at idle with a no-load for approximately 5 minutes, allowing the engine coolant to reach normal operating range, 88-96°C (190-210°F).
6. Visually inspect exhaust for excessive smoke.
   1. If the engine exhaust smoke emission appears normal, no further troubleshooting is required. Shut down the engine.
   2. If the engine exhaust smoke is excessively black or gray, shut down the engine. Check for worn or damaged valve or cylinder kit; refer to “7.2 Worn or Damaged Valve Guide/Seal or Cylinder Kit” .