To determine if a defective turbocharger is causing excessive exhaust smoke, perform the following:
1.Remove the charge air cooler inlet duct connected between the turbocharger and charge air cooler; see Figure 9-1.
2.Visually inspect the charge air cooler outlet duct.
[a] If excessive engine lube oil is present, refer to section 9.1.1.
[b] If no engine lube oil is present, check for worn or damaged valve or cylinder kit,
refer to section 9.2.
9.1.1
Turbocharger Replacement
Perform the following steps to replace a defective turbocharger:
1. Remove defective turbocharger from the engine; refer to appropriate service manual, air intake system chapter.
2. Tag removed turbocharger for remanufacture.
3. Install a replacement turbocharger to the engine; refer to appropriate service manual, air intake system chapter.
4. Verify replacement of new turbocharger; refer to section 9.1.1.1.
9.1.1.1
Test Engine with Replaced Turbocharger
Perform the following steps to determine if a replaced turbocharger resolved the excessive
exhaust smoke condition:
1. Start and run the engine.
2. 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).
3. Visually inspect exhaust for excessive smoke.
[a] If the engine exhaust smoke emission appears normal, no further troubleshooting is
required. Shut down the engine.
[b] 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 section 9.2.
