Wastegate valve adjusting

Special tools
Courtesy of VOLVO CARS OF NORTH AMERICA.	T9512985 GAUGE  Tool number:  T9512985 Tool description:  GAUGE Tool boards:
Courtesy of VOLVO CARS OF NORTH AMERICA.	T9512986 GAUGE  Tool number:  T9512986 Tool description:  GAUGE Tool boards:
Courtesy of VOLVO CARS OF NORTH AMERICA.	T9512775 CYLINDER LEAK TESTER  Tool number:  T9512775 Tool description:  CYLINDER LEAK TESTER Tool boards:

Remove any heat deflector shields if necessary

Before checking the adjustment of the wastegate, the wastegate arm should be lubricated so that it can be moved to its end positions.

Lubricate with universal oil or similar according to the markings in the image.

Install sensor 9512986 on the wastegate shaft.

Position the sensor so that the pin is about 2-5 mm from max pushed in position.

Ensure that the sensor is positioned to allow free movement with at least 15 mm in the direction of the wastegate shaft

Use pressure gauge, and pressure regulator

Install the following items: 

• 9512985
• 9512986
• 9512775

Before checking the adjustment of the wastegate valve, it should be possible to move the wastegate arm able to its outer positions.

1. Set the pressure to max according to the table by turning clockwise.
2. Note the movement of the wastegate arm.
3. Release the pressure completely by turning counter clockwise.

The arm should move relatively smoothly. Some rubbing may occur. Repeat steps 1-3 at least twice so that the arm moves smoothly.

1. Set the pressure to max according to the table.
2. Close the cock.
3. Disconnect the compressed air.
4. Check that the pressure does not drop more than 0.1 within 30 seconds.

Reset the instrument.

Check the wastegate as follows.

1. Reading off check value 1.
2. Setting max pressure.
3. Reading off check value 2.
4. Calculating the average value.

During this step it is important that the pressure is only adjusted upwards before reading off. 

If you have accidentally set too high a pressure, do not  fine adjust down. The reading will be incorrect.

If too high a pressure is reached, the pressure must be released completely and the adjustment must be restarted.

1. Connect the compressed air.
2. Ensure that the tap is fully open.
3. Set the control pressure for the actual engine version according to the table.
4. Read off the stroke and note check value 1.

During this step it is important that the pressure is only adjusted downwards before reading off. 

If you have accidentally set too low  a pressure, increase the pressure to the value for max pressure and then reduce to the correct control pressure according to the table. Otherwise the reading will be incorrect

1. Set the control pressure for the actual engine version according to the table.
2. Read off the stroke and note check value 2.
3. Release the pressure.

Calculate the average value by adding the measured value for check value 1 and 2 and divide by 2.

E.g. Measured check value 1: 5.7 mm

Measured check value 2: 8.3 mm

Average value = (5.7+ 8.3) / 2 = 7

Engine versions	Control pressure........bar	Average value check........mm	Average value adjustment........mm	Max pressure........bar
B5254T3, T6	0,380 +/-0,005	5 +/-0,5	5 +/-0,2	0,8
B5254T4 / B5244T5	0,700 +/-0,005	7 +/- 0,5	7 +/- 0,2	1,2

If the calculated average value is too small, the wastegate arm's tension must be reduced (counter clockwise).

If the calculated average value is too large, the wastegate arm's tension must be increased (clockwise).

One turn of the nut corresponds to 1 mm stroke.

Note that the steel arm is sensitive to turning and can deform easily. Use pliers as a counterhold.

1. Slacken off the nut
2. Adjust.

When adjusting, the instrument 9512985 can be used to see how much is adjusted.

Tighten the lock nut, pressure regulator. Tightening torque 7 Nm.

Note that the steel arm is sensitive to turning and can deform easily. Use pliers as a counterhold.

Post check by reading off check value 1 and 2 and calculating the average value.