Special Bulletin
Revision B:

SP16-301B
Date

Expiration

Release

Page

02.2016

02.2018

4

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This document supersedes previous revisions.
Procedure modified as per JZ

VARIABLE GEOMETRY TURBOCHARGER - ACTUATOR REPLACEMENT (SRA)

Prevost vehicles
DESCRIPTION
On the vehicles affected by this bulletin, replace the turbocharger actuator (SRA).

MODEL YEAR(S) AND VEHICLES INVOLVED
NOTICE TO SERVICE CENTERS
Verify vehicle eligibility by checking warranty bulletin status with SAP or via ONLINE WARRANTY
SYSTEM available on Service / Warranty tab of Prevost website.
Model
X3-45 Commuter
Model Year : 2012

VIN
From 2PCG33495CC735053 up to 2PCG33495CC735232 incl.

This bulletin does not necessarily apply to all the above-mentioned vehicles, some vehicles may have been modified
before delivery. The owners of the vehicles affected by this bulletin will be advised by a letter indicating the Vehicle
Identification Number (VIN) of each vehicle concerned.

MATERIAL NEEDED
Order kit “SP16-301” which consists in:
Part No.
85013731

Description
ACTUATOR, TURBOCHARGER – SERVICE KIT

Qty
1

NOTE
Material can be obtained through regular channels.

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Special Bulletin

SP16-301B
Date

Expiration

Release

Page

02.2016

02.2018

4

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PROCEDURE

DANGER
Park vehicle safely, apply parking brake, stop engine. Prior to working on the vehicle, set the ignition
switch to the OFF position and trip the main circuit breakers equipped with a trip button. On Commuter
type vehicles, set the battery master switch (master cut-out) to the OFF position.

PREPARATION
1. Apply the parking brake and shift the
transmission to neutral. Shut off all electrical
loads. Turn the ignition key to the OFF
position.

2. Open the engine compartment door. Set the
rear start selector switch to the OFF position
(FIGURE 1).

FIGURE 1

3. Using pressure wash equipment, clean the turbocharger actuator while it is still mounted.

Note: Make sure all electrical connections and coolant pipes in the area of the turbocharger actuator are
securely fastened.

4. Use a coolant extractor (FIGURE 2) to drain the
coolant from the engine. An alternate method
is to drain the coolant into a suitable container
using the drain hose.

FIGURE 2

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Special Bulletin

SP16-301B
Date

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Release

Page

02.2016

02.2018

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GAINING ACCESS TO THE AREA
5. In order to reach the turbocharger area, the
radiator coolant return pipe shown on FIGURE 3
along with the furthest flexible hose must be
removed.

FIGURE 3

6. Loosen the hose clamps (4 clamps) shown on
FIGURE 4.
7. Remove the two (2) U‐clamps shown on
FIGURE 4.

FIGURE 4

8. To ease removal, remove the transmission
dipstick tube clamp identified on FIGURE 5
(see also FIGURE 6: DIPSTICK TUBE CLAMP
REMOVED).
9. Take the coolant pipe out and the flexible hose
with it.

FIGURE 5: TRANSMISSION DIPSTICK TUBE CLAMP

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Date

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Page

02.2016

02.2018

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FIGURE 6: DIPSTICK TUBE CLAMP REMOVED

REMOVAL
10. Disconnect the actuator assembly electrical
connector at the wiring harness (FIGURE 7).
Cut any tie straps as needed.

FIGURE 7

11. Disconnect the coolant lines from the
actuator (FIGURE 8).

Caution: Protect the insides of the actuator
assembly and the exposed parts from
contamination when removed. Failure to do so
1) Coolant Return Port
can result in component malfunction or failure.

FIGURE 8

2) Coolant Inlet Port

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Date

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Page

02.2016

02.2018

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12. Unscrew the four hex socket head bolts (item
4) holding actuator to the turbocharger and
remove the actuator. Remove and discard
the gasket (FIGURE 9).

FIGURE 9

1) Alignment Pin
2) Actuator Housing
3) Gasket
4) Screw (4 Required)
5) Grease Applicator Tube

INSTALLATION
13. Using
gloves,
manually
rotate
the
turbocharger sector gear back and forth
(counterclockwise and clockwise) (FIGURE 10).
It should be noted that when the sector gear is
at the end of travel, or at an end stop, it can
require significant force to overcome friction
then, start its motion in the opposite direction.
This is normal and not cause for concern.
Apply more force to move the sector gear.
Once in motion, the sector gear movement
should be smooth, without binding or sticking
until it reaches its end of travel (end stop).
FIGURE 10

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Date

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Page

02.2016

02.2018

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14. Rotate the sector gear fully counterclockwise until
contact is made with the end stop of the variable
geometry internal mechanism. 1/4 to 3/4 of the
3mm (0.118 inch) reference hole should be visible
at the edge of the sector gear nearest the turbine
housing (FIGURE 11).

FIGURE 11
ALIGNMENT HOLE INSPECTION, 3MM (0.118 INCH) HOLE

15. For turbochargers manufactured without the small
3mm (0.118 inch) alignment hole, a portion (half)
of the 5mm (0.197 inch) alignment hole should be
exposed at the compressor housing side of the
sector gear when the sector gear is fully rotated
toward the turbine housing (FIGURE 12).

FIGURE 12
ALIGNMENT HOLE INSPECTION, 5MM (0.197 INCH) HOLE

16. Rotate the sector gear fully clockwise. Make
sure that the alignment pin fits through the
sector gear into the alignment hole in the
housing (FIGURE 13). The diameter of the
alignment hole is 5mm (0.197 inch).

Note: If the sector gear does not align properly
with the alignment hole or does not rotate
properly in either direction, replace the
turbocharger.
FIGURE 13

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