DOES THE TURBOCHARGER MAKE A
“WHINING ” OR “HOWLING” SOUND AS
IT SPINS UP OR SPINS DOWN.
NO
VISUALLY INSPECT ALL AIR INTAKE
HOSES FOR LEAKS.
INSPECT PURGE VALVE (150 ENGINE)
FOR CRACKINGORLEAKING.
PROBLEM SOLVED?
NO
INSPECT TURBINE AND COMPRESSOR BLADES FOR MECHANICAL /
PHYSICAL DAMAGE. REPLACE TURBOCHARGER ASSEMBLY IF ANY
DAMAGE IS FOUND.
INSPECT THE CHARGE AIR COOLER FOR PROPER OPERATION.
FRESHWATER INLET PRESSURE SHOULD BE AT LEAST 4 PSI.
REPLACE CHARGE AIR COOLER IF OUTLET AIR TEMP. @ WOT IS > THAN
THE FRESHWATERTEMP.+59_ F(15_ C.)
INSPECT THE WASTEGATE SOLENOID AND WASTEGATE FOR PROPER
OPERATION.
VERIFY THE BOOST REFERENCE HOSE LOCATED BETWEEN THE COM-
PRESSOR HOUSING AND WASTEGATE SOLENOID AND BETWEEN THE
SOLENOID AND WASTEGATE IS NOT BLOCKED WITH OIL OR FOREIGN
MATERIAL.
YES
USE THE DIGITAL WRENCHt SOFT-
WARE TO VERIFY WOT BOOST PRES-
SURE. DOES THE TURBOCHARGER
GENERATE THE SPECIFIED AMOUNT?
REPLACE THE TURBOCHARGER AS-
SEMBLY.
CHANGE THE ENGINE OIL AND FILTER
VERIFY THE QUALITY OF THE ENGINE
COOLANT.
FUEL INJECTION / IGNITION / EXHAUST SYSTEMS
5.34
2004 Four Stroke PWC Service Manual
Charge Air Cooler (Intercooler)
Whenever air is compressed, the air molecules within the air are packed tightly together and create friction be-
tween each other. The increased friction between the air molecules generates heat. A charge air cooler removes
most of the heat by transferring it to the freshwater cooling circuit.
Thecooler the air, the more lbs./min of air the compressor will pump into the engine.
Turbocharger / Charge Air Cooler -- Troubleshooting
A basic understanding of the turbocharger and charge air cooler must be obtained prior to troubleshooting each
component.
It is important to realize the engine WILL NOT achieve maximum RPM, and thus maximum performance if either
component is not working correctly.
Important Facts:
S The110 and 150 engine platforms utilize the same turbocharger assembly.
S The110 engine’s charge air cooler is smaller and thus, less efficient than the 150’s larger charge air
cooler. The incoming air in a 150 engine will be denser and contain more oxygen then that in a 110
engine.
S The110 engine does not utilize the air intake purge valve. The purge valve prevents boost spiking.
Boost spiking occurs when boost pressure rises abruptly when the throttle plate is closed by the oper-
ator.
S Theturbocharger is responsible for using spent exhaust gas energy to pre--compress incoming fresh
air.
S Thecharge air cooler is responsible for lowering the pre--compressed fresh air’s ambient tempera-
ture.
S During operation, carbon build up will occur on the turbocharger’s turbine blades. This is normal.
Never attempt to clean the turbine blades. Doing so will affect the balance and heat absorption char-
acteristics of each blade and may cause turbocharger failure.
Turbocharger / Charge Air Cooler Troubleshooting
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