1 page

INDEX1
Models J05C-TD, J08C-TP and J08C-TR TURBOCHARGER 51-1

51-28E-08

CHAPTER 51
TURBOCHARGER
Models J05C-TD, J08C-TP and J08C-TR

TROUBLESHOOTING ...............................................................51- 2

SPECIAL TOOLS ......................................................................51-10

TURBOCHARGER ....................................................................51-11

OVERHAUL FACTOR ...............................................................51-13

INSPECTION .............................................................................51-14

INSTALLATION .........................................................................51-19

51
 1 page 1
51-2 TURBOCHARGER Models J05C-TD, J08C-TP and J08C-TR

TROUBLESHOOTING
Table 1-1. Troubleshooting — Engine Lacks Power or Engine Exhaust Emits Black Smoke

SYMPTOM OR ENGINE LACKS ENGINE EXHAUST

POWER OR EMITS BLACK SMOKE
TROUBLE

POSSIBLE CAUSES AND REMEDIES

(See Notes A and H*) (See Note A*) (See Notes B and C*)

Dirty air cleaner

Viscosity of oil in Loose compressor-
element or inlet NO NO NO Leakage at engine NO
oil bath air to-intake-manifold
screen restricted in oil intake manifold
cleaner too high duct connections
bath air cleaner

YES YES YES YES

Replace air cleaner Service air cleaner in

Refer to engine
element or clean inlet accordance with Tighten duct connec-
manufacturer’s
screen in oil bath air engine manufacturer’s tions as required.
service manual.
cleaner. service manual.

(See Notes D, F and G*) (See Notes D and F*) (See Note K*) (See Note H*)

Restricted duct be-

Leakage at turbo- Turbocharger
Leakage at engine tween air cleaner
NO charger mounting NO rotating assembly NO NO
exhaust manifold and turbocharger
flange binding or dragging
compressor

YES YES YES YES

Check condition of
Refer to engine Perform trouble- Remove restriction
gasket at turbocharger
manufacturer’s shooting procedures or replace damaged
mounting flange and
service manual. outlined in Table 1-7 parts as necessary.
tighten loose bolts.

(See Note H*.)

Engine malfunction
Restricted duct be- Restricted engine Restricted engine (fuel system compo-
tween compressor exhaust system NO NO
NO intake or exhaust nent, valves, valve
and engine intake (after turbocharger) manifold timing, rings, pistons,
manifold
etc)

YES YES YES YES

Remove restriction Remove restriction Refer to engine Refer to engine

or replace damaged or replace damaged manufacturer’s manufacturer’s
parts as necessary. parts as necessary. service manual. service manual.

*Shown on Table 1-9.

 1 page 1
Models J05C-TD, J08C-TP and J08C-TR TURBOCHARGER 51-3

Table 1-2. Troubleshooting — Engine Exhaust Emits Blue Smoke

SYMPTOM OR ENGINE EXHAUST

TROUBLE EMITS BLUE SMOKE

POSSIBLE CAUSES AND REMEDIES

(See Notes A and H*) (See Note A*) (See Notes B and C*) (See Note F*)

Dirty air cleaner

Viscosity of oil in Loose compressor-to-
element or inlet Leakage at engine
NO oil bath air cleaner NO intake-manifold duct NO NO
screen restricted in oil intake manifold
too high connections
bath air cleaner

YES YES YES YES

Replace air cleaner Service air cleaner in

Tighten duct Refer to engine
element or clean inlet accordance with
connections as manufacturer’s
screen in oil bath air engine manufacturer’s
required. service manual.
cleaner. service manual.

(See Note H*)

Restricted duct be-

Seal leakage at Engine malfunction
Plugged engine oil tween air cleaner
NO NO compressor end of NO (rings, pistons,
filter and turbocharger
turbocharger valves, etc)
compressor

YES YES YES YES

Service oil filter in Refer to engine

Remove restriction or Perform troubleshoot-
accordance with manufacturer’s
replace damaged ing procedures out-
engine manufacturer’s service manual.
parts as necessary. lined in Table 1-6
service manual.

*Shown on Table 1-9

Table 1-3 Troubleshooting — Engine Oil Consumption Excessive

ENGINE OIL
SYMPTOM OR
CONSUMPTION
TROUBLE
EXCESSIVE

POSSIBLE CAUSES AND REMEDIES

Seal leakage at com-

Seal leakage at turbine Oil in engine exhaust
Wrong type or vis- pressor end of turbo-
end of turbocharger manifold (indicating
cosity of engine NO chager (indicated by oil NO NO
(indicated by oil in malfunction of rings,
lubricating oil in housing or on
housing or on wheel) pistons, valves, etc)
wheel)

YES YES YES YES

Service engine lube

Perform troubleshoot- Perform troubleshoot- Refer to engine
system in accordance
ing procedures out- ing procedures out- manufacturer’s
with engine manufac-
lined in Table 1-6 lined in Table 1-7 service manual.
turer’s service manual.
 1 page 1
51-4 TURBOCHARGER Models J05C-TD, J08C-TP and J08C-TR

Table 1-4. Troubleshooting — Noisy Turbocharger

SYMPTOM OR TURBOCHARGER
TROUBLE NOISY

POSSIBLE CAUSES AND REMEDIES

(See Notes A and H*) (See Notes H*)

Dirty air cleaner Foreign object or Foreign object or

Foreign object in
element or inlet material in compres- material in compres-
NO NO NO engine exhaust NO
screen restricted in sor inlet ducting or sor to intake manifold
system
oil bath air cleaner compressor housing ducting

YES YES YES YES

Remove foreign ob- Remove foreign ob- Remove foreign ob-

Replace air cleaner
ject. Repair air intake ject. Repair air intake ject. Repair exhaust
element or clean inlet
system and overhaul system and overhaul system and overhaul
screen in oil bath air
turbocharger as turbocharger as turbocharger as
cleaner.
necessary. necessary. necessary.

Carbon build-up in Turbocharger rotating

turbine housing NO assembly binding or
dragging

YES YES

Clean housing or
overhaul turbocharger Perform troubleshoot-
as required. ing procedures out-
Check engine operat- lined in Table 1-5
ing procedures.

*Shown on Table 1-9.

 1 page 1
Models J05C-TD, J08C-TP and J08C-TR TURBOCHARGER 51-5

Table 1-5. Troubleshooting — Turbocharger Rotating Assembly Binding or Dragging

TURBOCHARGER
SYMPTOM OR ROTATING ASSEMBLY
TROUBLE BINDING OR DRAGING

POSSIBLE CAUSES AND REMEDIES

(See Notes J*)

Damaged compressor Damaged turbine Compressor wheel or Excessive dirt build-

wheel due to foreign NO wheel due to foreign NO turbine wheel rubbing NO up in compressor (on NO
object impact object impact on housing housing or wheel)

YES YES YES YES

Worn bearings, shaft Clean and repair air

Clean and repair air Clean and repair en-
journals, or bearing intake system as
intake system as gine exhaust system as
bores. Troubleshoot necessary. Clean
necessary. Overhaul necessary. Overhaul
as outlined in compressor or over-
turbocharger. turbocharger.
Table 1-8 haul turbocharger.

(See Notes I*)

Excessive carbon
Sludged or coked
build-up behind NO center housing
turbine wheel

YES YES

Coked oil combustion Service engine lu-

deposits. Overhaul brication system.
turbocharger. Overhaul turbocharger.

*Shown on Table 1-9

 1 page 1
51-6 TURBOCHARGER Models J05C-TD, J08C-TP and J08C-TR

Tabla 1-6. Troubleshooting — Seal Leakage at Compressor End of Turbocharger

SEAL LEAKAGE AT
SYMPTOM OR
COMPRESSOR END
TROUBLE
OF TURBOCHARGER

POSSIBLE CAUSES AND REMEDIES

Dirty air cleaner Restricted duct be-

Viscosity of oil in Loose compressor-to-
element or inlet tween air cleaner
NO oil bath air cleaner NO NO intake-manifold duct NO
screen restricted in and turbocharger
too high connection
oil bath air cleaner compressor

YES YES YES YES

Replace air cleaner Service air cleaner in

Remove restriction
element or clean inlet accordance with Tighten duct connec-
or replace damaged
screen in oil bath air engine manufacturer’s tions as required.
parts as necessary.
cleaner. service manual.

Restricted turbo- Worn or damaged

Leakage at engine Plugged engine crank-
NO charger oil drain NO NO compressor wheel NO
intake manifold case breather
line

YES YES YES YES

Clean and remove Clean and repair air

Refer to engine Refer to engine
restriction or replace intake system as
manufacturer’s manufacturer’s
oil drain line as necessary. Overhaul
service manual. service manual.
required. turbocharger.

Engine malfunction
Turbocharger bearings, (excessive piston
bearing bores, or shaft NO blowby or high
journals worn internal crankcase
pressure)

YES YES

Perform trobleshoot- Refer to engine

ing procedures out- manufacturer’s
line in Table 1-8 service manual.
 1 page 1
Models J05C-TD, J08C-TP and J08C-TR TURBOCHARGER 51-7

Table 1-7. Troubleshooting — Seal Leakage at Turbine End of Turbocharger

SEAL LEAKAGE AT
SYMPTOM OR
TURBINE END OF
TROUBLE
TURBOCHARGER

POSSIBLE CAUSES AND REMEDIES

Restricted turbo-
Excessive pre-oiling Plugged engine crank- Sludged or coked
NO NO chager oil drain NO NO
case breather center housing
line

YES YES YES YES

Clean and remove Service engine lu-

Refer to engine
Oil will burn away. restriction or brication system.
manufacturer’s
No action required. replace oil drain line Overhaul turbo-
service manual.
as required. charger.

Engine malfunction
Turbocharger bear-
(excessive piston
ings, bearing bores,
NO blowby or high in-
or shaft journals
ternal crankcase
worn
pressure)

YES YES

Perform trobleshoot- Refer to engine

ing procedures out- manufacturer’s
lined in Table 1-8 service manual.
 1 page 1
51-8 TURBOCHARGER Models J05C-TD, J08C-TP and J08C-TR

Tabla 1-8. Troubleshooting — Turbocharger Bearings, Bores, or Journals are Worn

TURBOCHARGER
SYMPTOM OR BEARINGS, BORES,
TROUBLE OR SHAFT JOURNALS
WORN*

POSSIBLE CAUSES AND REMEDIES

Inadequate pre-oiling Contaminated or im- Insufficient engine

Restricted turbo-
following turbocharger proper grade or type oil supplied to
NO NO NO charger oil feed NO
installation or engine of engine lubricating turbocharger due to
line
lube system servicing oil used in engine "oil lag"

YES YES YES YES

Service engine lube

Follow proper Remove restriction
Follow pre-oiling system in accordance
engine operating or replace damaged
instructions. with engine manufac-
procedures. parts as necessary.
turer’s service manual.

Abrasive wear due to Insufficient lube oil

flaking of coked supplied to turbo-
Plugged engine oil
NO particles from center NO charger due to
filter
housing interior engine oil pump
surfaces malfunction

YES YES YES

Service engine lube

Refer to engine Refer to engine
system in accordance
manufacturer’s manufacturer’s
with engine manufac-
service manual. service manual.
turer’s service manual.

*Overhaul turbocharger, then use this table to determine cause of failure.

 1 page 1
Models J05C-TD, J08C-TP and J08C-TR TURBOCHARGER 51-9

Table 1-9. Troubleshooting Procedures Notes

A. Refer to engine manufacturer’s service manual for inspection requirements and replacement speci-
fications.

B. With engine stopped, check duct clamping devices for tightness.

C. With engine running at idle speed, lightly spray duct connections with starting fluid. Leaks at connec-
tions will be indicated by an increase in engine speed due to the starting fluid being drawn into the
compressor and pumped into the engine combustion chambers.

D. With engine running at idle speed, check duct connections for leaks by applying lightweight oil or
liquid soap to areas of possible leakage and checking for bubbles. Exhaust gas leakage between the
engine block and the turbocharger inlet will also create a noise level change.

E. With engine running at idle speed, check for unusual noise and vibration. If either condition is noted,
shut down the engine immediately to protect the turbocharger and engine from further damage. With
the engine stopped, check the turbocharger shaft wheel assembly for damage as outlined Note I,
below.

F. With engine running, a change in the noise level to a higher pitch can indicate air leakage between
the air cleaner and the engine or a gas leak between the engine block and the turbocharger inlet.

G. Exhaust gas leakage may be indicated by heat discoloration in the area of the leak.

H. With the engine running, noise level cycling from one level to another can indicate a plugged air
cleaner, a restriction in the air-cleaner to compressor duct, or a heavy build-up of dirt in the compres-
sor housing or on the compressor wheel.

I. Internal inspection of the center housing can be accomplished by removing the oil drain line and
looking through the oil drain opening. When a sludged or coked condition exists, a heavy sludge
build-up will be seen on the shaft between the bearing journals and in the center housing from the oil
drain opening back to the turbine end.

J. Thorough cleaning of the air intake system is essential following compressor wheel damage due to
foreign object impact. In many cases, metal pieces from the wheel become imbedded in the air
cleaner element. If the element is not changed, these metal pieces can be drawn into the replace-
ment turbocharger and cause it to fail in the same manner as the original unit.

K. With the air inlet and exhaust gas ducting removed from the turbocharger, examine both the com-
pressor and turbine wheels for blade damage. Examine the outer blade tip edges for evidence of
rubbing on housing surfaces.

Turn the rotating assembly by hand and feel for dragging or binding. Push the rotating assembly
side-ways while rotating to feel for wheel rub. If there is any indication of rubbing, perform the
bearing clearance inspection procedure. If the rotating assembly rotates freely and there is no evi-
dence of binding or rubbing, it can be assumed that the turbocharger is serviceable.
 1 page 1
51-10 TURBOCHARGER Models J05C-TD, J08C-TP and J08C-TR

SPECIAL TOOLS
Prior to starting a turbocharger overhaul, it is necessary to have this special tool.

Illustration Tool No. Tool Name Use

For measuring the turbine

09444 - 1130 END PLAY GAUGE shaft end play with a dial
gauge.
 1 page 1
Models J05C-TD, J08C-TP and J08C-TR TURBOCHARGER 51-11

TURBOCHARGER

ENGINE MODEL: 3 13
J05C-TD
14 12 11 8

10

5 23 9
24 25 26 1

20 19 18 17 16 15 7 6
2 22 21

5 4

1. Turbine housing 14. Hexagon nut

2. Compressor housing 15. Turbine wheel assembly
3. Actuator assembly 16. Piston ring
4. Clamp 17. Wheel shroud
5. Bolt 18. Spacer
6. Elbow assembly 19. Journal bearing
7. Bolt 20. Seal ring
8. Retaining ring 21. Piston ring
9. O-ring 22. Compressor wheel
10. Label caution 23. Back plate
11. Rod end 24. Thrust collar
12. Rod end nut 25. Thrust bearing
13. Actuator bracket 26. Center housing

SM51-J005
Fig. 1
 1 page 1
51-12 TURBOCHARGER Models J05C-TD, J08C-TP and J08C-TR

ENGINE MODEL: 8
J08C-TP, J08C-TR 10
9

13 11 12

7 6

20
22
17

19 18 3 16 15 24 14 23 1

2 21 5 4

1. Turbine housing 13. Hexagon nut

2. Compressor housing 14. Piston ring
3. Center housing 15. Bearing journal
4. Clamp 16. Spacer
5. Bolt 17. Thrust bearing
6. Actuator bracket 18. Thrust collar
7. Actuator assembly 19. Seal ring
8. Hexagon nut 20. Backplate
9. Hose 21. Compressor wheel
10. Hose clamp 22. O-ring
11. Rod end 23. Turbine wheel assembly
12. Retaining ring 24. Wheel shroud

SM51-J0061
Fig. 2
 1 page 1
Models J05C-TD, J08C-TP and J08C-TR TURBOCHARGER 51-13

OVERHAUL FACTOR
CONDITIONS WHICH DETERMINE WHEN A TURBO-
CHARGER OVERHAUL MAY BE NEEDED.
1. ON-ENGINE TROUBLESHOOTING
The most common symptoms of turbocharger fail-
ure are related to engine performance:
● Lack of power
● Excessive exhaust smoke
● Unusual noise
● Excessive oil or fuel consumption.
NOTE: Any of these symptoms could be the result
of an internal engine problem, and might not
involve the turbocharger at all.

The troubleshooting procedure contain these six

steps:
1. Examine the turbocharger exterior and installation.
2. Examine turbine wheel and housing.
3. Examine compressor wheel and housing.
4. Check rotating assembly for noise or excessive play.
5. Check axial bearing clearances.
6. Check wastegate performance.
 1 page 1
51-14 TURBOCHARGER Models J05C-TD, J08C-TP and J08C-TR

INSPECTION
WARNING
Do not work on the turbocharger while it is still hot.
This can result personal injury.

1. EXAMINE THE TURBOCHARGER EXTERIOR AND

INSTALLATION.
Visually check for:
● Missing or loose nuts and bolts.
● Loose or damaged intake and exhaust pipe.
● Damaged oil supply and drain lines.
● Cracked or deteriorating turbocharger housings.
● External oil or coolant leakage.
Correct any installation problems. If turbocharger
parts are damaged, the unit should be overhauled
after completion of the remainder of this troubleshoot-
ing procedure.

WARNING
Operation of the turbocharger without the intake
pipe and air cleaner connected can result in per-
sonal injury and damage to equipment from foreign
objects entering the turbocharger.

2. REMOVE THE INTAKE AND EXHAUST PIPE.

1. Remove the fitting bolts and loosen the rubber hose
clamp.
2. Remove the intake pipe from the turbocharger.

SM51-J009
Fig. 3 Model J05C-TD

SM51-J010
Fig. 4 Model J08C-TP, J08C-TR
6
 1 page 1
Models J05C-TD, J08C-TP and J08C-TR TURBOCHARGER 51-15

3. Remove the exhaust insulator and bracket.

FITTING NUT
4. Remove the bolts and the fitting nuts.
5. Remove the exhaust pipe from the turbocharger.
EXHAUST
INSULATOR

EXHAUST
PIPE
BRACKET
BOLT BOLT SM51-057
Fig. 5
3. EXAMINE TURBINE WHEEL AND HOUSING.
Remove the ducting from the turbine outlet. Using a
flash-light, check the turbine for wheel to housing rub
(Fig. 6), evidence of oil leakage or foreign object dam-
age. Foreign object damage to the turbine is not usu-
ally visible through the turbine outlet unless the dam-
age is severe.

1. Wheel to housing rub

If wheel rub is found, and the housing attaching hard-
ware is secure, then the turbocharger is probably
damaged internally and must be overhauled.

2. Oil leakage
If oil deposits are found, determine whether the oil
has come from the engine exhaust or from the tur-
SM51-J002 bocharger center housing.
Fig. 6 Turbine wheel to housing rub If the oil has come from the engine, consult CHAP-
TER 3 ENGINE and correct the problem. If oil de-
posits on the wheel are heavy the turbocharger
should be disassembled, cleaned, and overhauled if
necessary.

3. Foreign object damage

If foreign object damage to the turbine is visible, the
turbocharger must be overhauled. Such damage
destroys the wheel’s balance and causes internal
damage to the seal bores and journal bearings. Be
sure to find the source of the foreign object. In many
cases, the object has come out of the engine, and
there may be engine damage as well.
 1 page 1
51-16 TURBOCHARGER Models J05C-TD, J08C-TP and J08C-TR

4. EXAMINE COMPRESSOR WHEEL AND HOUSING.

Remove the ducting from the compressor inlet. Us-
ing a flashlight, check the compressor for wheel to
housing rub (Fig. 7), evidence of oil leakage, or for-
eign object damage.

1. Wheel to housing rub

If wheel rub is found, and the housing attaching hard-
ware is secure, then the turbocharger is probably
damaged internally and must be overhauled.

2. Oilleakage
Oilleakage into the compressor can be caused by:
1. Long periods of idling on a restricted oil drain line.
2. Oil leakage into the compressor can also be
caused by a restricted air intake system.
3. Oil leakage into the compressor can be caused
SM51-J003 by frequent use of the engine as a brake. In this
Fig. 7 Compressor wheel to housing rub case, nothing is wrong with either the engine or
the turbocharger, but frequent compressor wheel
and housing clean-up is recommended.

3. Foreign object damage

If the compressor wheel has been damaged by a
foreign object, the turbocharger must be overhauled.
 1 page 1
Models J05C-TD, J08C-TP and J08C-TR TURBOCHARGER 51-17

5. CHECK ROTATING ASSEMBLY FOR NOISE OR EX-

CESSIVE PLAY.
If no damage is visible in the turbine and compres-
sor areas, spin the rotating assembly by hand. It
should spin freely with no drag or grinding noises.

SM51-002A
Fig. 8

OIL INLET PIPE

6. REMOVE THE TURBOCHARGER.
1. Remove the clamp bolt and oil inlet pipe.
COOLANT
PIPE CLAMP BOLT 2. Remove the coolant pipes
3. Remove the oil outlet pipe

OIL
OUTLET
PIPE
SM51-J012
Fig. 9
5

COOLANT
PIPE

OIL OUTLET PIPE

SM51-J003
Fig. 10
4
4. Remove the turbocharger from the exhaust manifold.

SM51-J014
Fig. 11
2 7. CHECK AXIAL BEARING CLEARANCES.
1. Check the turbine rotor (exhaust side) for axial play
using a special tool and dial gauge.
Special tool: 09444 - 1130
Service limit: 0.025 - 0.08 mm (0.0010 - 0.0031 in.)
2. If the measurement is out of service limit, the turbo-
charger is worn or damaged internally and must be
overhauled.
SM51-111
Fig. 12
 1 page 1
51-18 TURBOCHARGER Models J05C-TD, J08C-TP and J08C-TR

8. CHECK WASTEGATE PERFORMANCE.

1. Remove hose clamps and hose from wastegate
sensing port.
2. Attach a dial gauge, set to the turbocharger so that
DIAL GAUGE the dial gauge rests on the end of the actuator rod in
the plane of the rod, as applicable.
3. Set the dial indicator to zero.
4. While gently tapping the turbine housing with a soft
SM51-J007 mallet, apply air pressure until the dial gauge pointer
Fig. 13 Model J05C-TD shows as follows.
DIAL GAUGE
Rod Movement: 0.38 mm (0.015 in.)
5. Make sure that the air pressure is within the speci-
fied value.
Specified air pressure: Unit: mmHg (inHg)
Engine model Air pressure
J05C-TD 715 - 765 (28.1 - 30.1)
J08C-TP, J08C-TR 1,125 - 1,175 (44.3 - 46.2)
SM51-J008
Fig. 14 Model J08C-TP, J08C-TR
3
6. Release the air pressure at the sensing port. Note
that the dial gauge pointer returns exactly to zero.
7. Repeat steps 4 through 6 several times to make sure
that the air pressure has been accurately measured.
8. If the air pressure cannot be obtained within the
specified value, the turbine housing assembly or
actuator assembly must be replaced.
NOTE: Operation of the engine with the wastegate
calibrated to some value other than that
specified can result in reduced performance
or severe engine damage.
9. If wastegate performance is within specification, in-
stall the hose onto the wastegate sensing port.
 1 page 1
Models J05C-TD, J08C-TP and J08C-TR TURBOCHARGER 51-19

INSTALLATION
1. MOUNT THE TURBOCHARGER.
1. Mount the turbocharger on the exhaust manifold
using a new gasket.
Tightening Torque: 570 kg·cm (41 lb·ft)

SM51-J014
Fig. 15
2 2. Install the oil outlet pipe.
3. Install the coolant pipes.
4. Install the oil inlet pipe and clamp bolt.

COOLANT PIPE

OIL OUTLET PIPE

SM51-J013
Fig. 16
4
OIL INLET PIPE

COOLANT CLAMP BOLT

PIPE

OIL OUTLET
PIPE
SM51-J012
Fig. 17
5 5. Mount the exhaust pipe from the turbocharger.
FITTING NUTw 6. Install the bracket.
7. Temporarily tighten the bolt q, the fitting nuts w, and
EXHAUST
INSULATOR the bolts e in that order, and securely contact the
fitting surfaces.
8. Tighten the bolts and the nuts to the specified torque
EXHAUST
PIPE in numerical order.
BRACKET Tightening Torque:
BOLTq BOLTe SM51-057
560 kg·cm (40 lb·ft) for the bolts q and e
Fig. 18
300 kg·cm (21 lb·ft) for the nuts w
9. Install the exhaust insulator.
 1 page 1
51-20 TURBOCHARGER Models J05C-TD, J08C-TP and J08C-TR

10. Mount the intake pipe and tighten the fitting bolts.

SM51-009
Fig. 19 Model J05C-TD
7

SM51-010
Fig. 20 Model J08C-TP, J08C-TR
6