Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Circuit/System Testing
- Verify the conditions listed below do not exist:
- Vacuum leaks
- Vacuum line restrictions
- Improper routing or connecting of the vacuum hoses on the Q40 Turbocharger Bypass Solenoid Valve, the bypass valve, and the bypass valve vacuum reservoir
- If a condition exists
Repair or replace the component as necessary.
- Go to next step: If none of the conditions exist
- Disconnect the Q40 Turbocharger Bypass Solenoid Valve vacuum supply hose at the intake manifold.
- Connect the GE 23738-A to the manifold.
- Engine Idling, verify the vacuum gauge displays between 45 - 67 kPa (13 - 20 inches Hg) of vacuum.
- If not within the specified range
Repair the vacuum source.
- Go to next step: If within the specified range
- If not within the specified range
- Ignition OFF, disconnect the vacuum hose at the turbocharger vacuum reservoir.
- Connect the GE 23738-A to the vacuum reservoir and apply 34 kPa (10 inches Hg) of vacuum.
- Verify the reservoir holds vacuum for at least 10 s.
- If the vacuum is not held for at least 10 s
Replace the intake manifold
- Go to next step: If the vacuum is held for at least 10 s
- If the vacuum is not held for at least 10 s
- Connect the vacuum hose to the reservoir.
- Disconnect the vacuum hose at the turbocharger bypass valve and connect the GE 23738-A to the hose.
- Engine idling, command the Turbocharger Bypass Solenoid Valve ON and OFF with a scan tool.
- Verify the vacuum toggles between 0 kPa (0 inches Hg) to greater than 45 kPa (13 inches Hg).
- If not within the specified range
Test or replace the Q40 turbocharger bypass solenoid valve
- Go to next step: If within the specified range
- If not within the specified range
- Connect any hoses that were disconnected during previous steps.
- Verify damage to the turbocharger bypass valve assembly does not exist. Refer to Compressor Air Intake Turbocharger Cleaning and Inspection
.
- If the turbocharger bypass valve assembly is damaged
Repair or replace the turbocharger bypass valve assembly as necessary.
- Go to next step: If the turbocharger bypass valve assembly is not damaged
- If the turbocharger bypass valve assembly is damaged
- Replace the turbocharger.
Allow engine idle to stabilize before continuing.
The vacuum reservoir (tank) is integral to intake manifold and is located at the bottom of the manifold.
The Q40 Turbocharger Bypass Solenoid Valve is supplied with vacuum from both the intake manifold and the vacuum reservoir at idle. The vacuum supply hose from the intake manifold must be disconnected before proceeding, to allow vacuum to bleed off when changing command states.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.