UENR0623-02 67 Air Inlet and Exhaust System 1. Follow steps 1.a to 1.i in order to test the coolant side of the exhaust gas cooler (NRS). a. Plug the coolant inlet of the exhaust gas cooler (NRS). b. Plug the coolant outlet port with tube and pressure regulator assembly. c. Make sure that the air pressure regulator is closed and connect compressed air to the pressure regulator. d. Use a suitable air supply in order to apply an air pressure of 250 kPa (36 psi) to the exhaust gas cooler (NRS). e. While the exhaust gas cooler (NRS) is still pressurized, submerge the cooler in water that is at ambient temperature. Illustration 57 g02529617 Typical example f.
Allow the exhaust gas cooler (NRS) to settle in order for the air that is trapped to escape. g. Observe the exhaust gas cooler (NRS) for air bubbles that indicate a leak. If air bubbles are seen within 3 minutes, this indicates a leak with the exhaust gas cooler (NRS). Note the location or the origin of the leak. Record this information. 1. Disconnect the pipe for the boost sensor (1) at the wastegate actuator (2). Connect an air supply to the wastegate actuator that can be adjusted accurately. 2. Install Tooling (A) to the turbocharger so that the end of the actuator rod (3) is in contact with Tooling (A). This will measure axial movement of the actuator rod (3). h.
If no bubbles are detected after 3 minutes, the exhaust gas cooler (NRS) is reusable. 3. Slowly apply air pressure to the wastegate so that the actuator rod (3) moves 10 mm (0.3937 inch). Refer to Specifications, “Turbocharger” for the correct pressure for the wastegate. Ensure that the dial indicator returns to zero when the air pressure is released. Repeat the test several times. This will ensure that an accurate reading is obtained. i. Remove the exhaust gas cooler (NRS) from the water. If the exhaust gas cooler (NRS) does not leak, the problem may be elsewhere in the cooling system or the engine. Refer the service manual in order to check for leakage.
If the exhaust gas cooler (NRS) does leak, the exhaust gas cooler (NRS) should be replaced. 2. Follow steps 2.a to 2.i in order to test the gas side of the exhaust gas cooler (NRS). 4. If the operation of the wastegate is not correct, the turbocharger will need to be replaced. a. Plug the gas inlet of the exhaust gas cooler (NRS). 5. Repeat steps 2 to 3 in order to repeat the pressure test. b. Plug the gas outlet port with tube and pressure regulator assembly. 6. If the air pressure is correct, remove the air supply. Remove Tooling (A). Install the pipe for the boost sensor (1). c. Make sure that the air pressure regulator is closed and connect compressed air to the pressure regulator.
i04552042 Exhaust Cooler (NRS) - Test d. Use a suitable air supply in order to apply an air pressure of 250 kPa (36 psi) to the exhaust gas cooler (NRS). Air Under Water Leak Test Procedure . e. While the exhaust gas cooler (NRS) is still pressurized, submerge the cooler in water that