Series 50G & 60G Troubleshooting

Section 8.5 Series 60G Recirculation Valve

Section 8.5
Series 60G Recirculation Valve

The Series 60G turbocharger requires a boost recirculation valve to reduce air system pressure pulsations and turbocharger surging during engine throttling operations. The recirculation valve is remote-mounted by the OEM and routes air from the high-pressure boost side back to the air inlet side during deceleration. The recirculation valve is a large solenoid valve that is triggered to open by DDEC through a digital output pin of the ECM. See Figure "Series 60G Recirculation Valve" for recirculation valve.‪

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1. Recirculation Valve Body‪

3. 2-pin Connector‪

2. 12V Coil‪

4. Bracket‪

Figure 1. Series 60G Recirculation Valve

Section 8.5.1
Testing of Series 60G Recirculation Valve Operation

Confirm proper operation of the Series 60G recirculation valve as follows:‪

  1. Perform a Stall Test as follows (repeat as necessary):
    1. Accelerate the engine in low gear, brakes applied.
    2. Slowly increase the engine rpm from idle to stall (0 to 100% throttle).
    3. Once stall rpm is reached, immediately let the throttle go back to 0%.
  2. As the throttle goes back to 0%, listen for a "whoooosh" sound.
    1. If there is a "whoooosh" sound, then replace the Low Pressure Regulator and follow the Learn Procedure, refer to "8.7 Fuel System Learn Procedure" .
    2. If there is no "whoooosh", then plug the Diagnostic Data Reader (DDR) or theDetroit Diesel Diagnostic Link (DDDL) into the Diagnostic Connector. Repeat step 1 and read the Y-3 digital output as the throttle goes back to 0%.
    3. If the Y-3 digital output is not triggering the valve to open, then check vehicle wiring. Refer to the vehicle OEM service manual.
    4. If the Y-3 digital output is triggering the valve to open, then replace the Series 60G recirculation valve. Refer to "8.5.2 Removal of Series 60G Recirculation Valve" .

Section 8.5.2
Removal of Series 60G Recirculation Valve

Remove the Series 60G Recirculation Valve as follows: ‪

Note: The recirculation valve is a non-serviceable component and should be replaced as a unit. No adjustment is required.

  1. Disconnect the inlet and outlet hoses from the recirculation valve.
  2. Disconnect the two-pin electrical connector.
  3. Remove the two bolts that attach the recirculation valve to the mounting surface.

    NOTICE:

    The valve has a mounting bracket attached to its body. Do not remove the bolts in the valve body to gain access to the valve. Removal of these bolts can expose the valve diaphragm and cause permanent damage.‪

  4. If replacing the unit, remove the inlet and outlet fittings from the valve.

Section 8.5.3
Installation of Series 60G Recirculation Valve

Install the Series 60G Recirculation as follows: ‪

  1. If replacing the unit, install the inlet and outlet fittings removed from the old valve.
  2. Position the valve on the mounting surface and secure it in place with the two mounting bolts.

    Note: The arrow on the base of the valve should correspond with the flow of air from the turbo outlet side to the turbo inlet side.

  3. Connect the inlet and outlet hoses to the valve fittings.
  4. Connect the two-pin electrical connector.
  5. Start the engine and check for any leaks in the system. Repair leaks as required.


Series 50G and 60G Troubleshooting Guide - 6SE482
Generated on 10-13-2008

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