Usage:
1. Remove the air cleaner.
2. Disconnect and plug lines (1) and (2). Remove the elbow and flange and the gaskets.
3. Disconnect exhaust elbow (3) and air tube (4).
4. Attach a strap and hoist to the turbocharger.
5. Remove bolts (5) and turbocharger (6). The weight of the turbocharger is approximately 100 kg (220 lb).
NOTE: The following steps are for installation of the turbocharger.
6. Put turbocharger (6) in position. Put 5P3931 Anti-Seize Compound on the threads of bolts (5) and install them. Tighten the bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
7. Remove the strap and hoist.
8. Connect air tube (4) and exhaust tube (3). Put 5P3931 Anti-Seize Compound on the threads of the bolts for the exhaust tube and tighten them to a torque of 200 ± 25 N·m (150 ± 20 lb ft).
9. Install the elbow and flange and gaskets. Connect lines (1) and (2).
10. Install the air cleaner.
Disassemble And Assemble Turbocharger
Start By:
a. remove turbocharger
1. Mark the three housings of the turbocharger for proper alignment at assembly.
2. Attach tooling (A) and a hoist to the turbocharger. The weight of the turbocharger is approximately 100 kg (220 lb). Remove eight bolts (1), the lock plates, and four straps (2).
NOTE: If the branch position of the housings are changed, the housings must first be separated by a minimum of 2 mm (.08 in) to prevent the diffuser from scratching the compressor housing.
3. To remove turbine housing (3), raise the turbocharger a small amount and tap on the turbine housing.
4. Put tool (B) in a vice and set the turbocharger in tool (B) as shown. Remove bolts (5), the washers, straps (6) and compressor housing (4).
5. Remove diffuser (7).
| NOTICE |
|---|
To prevent a bent shaft, do not put a side force on the turbine shaft when the compressor wheel nut is loosened. |
6. Use a universal joint and a socket of the correct size to remove nut (8) and the washer. Remove seal (9).
| NOTICE |
|---|
Be prepared to catch the turbine when the shaft breaks loose from the compressor wheel. |
7. Put the cartridge group in a press as shown. Apply enough pressure to break the shaft free from the compressor wheel.
8. Put the cartridge group in tool (B) and remove compressor wheel (10).
9. Use tooling (C) to remove retaining ring (11).
10. Remove ring (12), cover (13), shield (15), and ring (17). Remove ring (16) from ring (12) and O-ring seal (14) from cover (13).
11. Remove three bolts (18) and the lockwashers.
12. Remove the retainer, bearing (19), and ring (20).
13. Remove the housing assembly from shaft and wheel assembly (21).
14. Separate housing (22) from shroud (23) and remove housing (22).
15. Remove plug (24).
16. Remove two bolts (25) and two bearings (26).
17. Remove shroud (23) and seal ring (27).
NOTE: The following steps are for assembly of the turbocharger.
NOTE: Put clean engine oil on all parts of the cartridge group during assembly.
18. Put 6V2055 High Vacuum Grease in the groove for seal ring (27). Make sure the grease fills the groove approximately one half or more of the groove depth for the complete circumference of the groove to help make a carbon dam under the seal ring. Install seal ring (27) and shroud (23).
19. Install two bearings (26). Clean the threads of bolts (25) with 6V1541 Quick Cure Primer and put 9S3265 Retaining Compound on them. Install bolts (25). Tighten the bolts to a torque of 12 ± 4 N·m (9 ± 3 lb ft).
20. Install plug (24) and tighten it to a torque of 70 ± 10 N·m (52 ±7 lb ft).
21. Install housing (22).
22. Install ring (20) and bearing (19). Be sure the hole in bearing (19) is lined up with the locating pin. Install the retainer, the lockwashers and bolts (18).
23. Install ring (16) on ring (12) and O-ring seal (14) on cover (13). Install ring (17), shield (15), cover (13) and ring (12).
24. Use tooling (C) and install retaining ring (11).
25. Put compressor wheel (10) in position on the shaft. Place the cartridge group in a press and press the compressor wheel onto the shaft.
| NOTICE |
|---|
Angularity (straightness) of nut (8) must be precise. Do not reuse nut (8) more than three times. |
| NOTICE |
|---|
To prevent a bent shaft, do not put a side force on the turbine shaft when the compressor wheel nut is tightened. |
26. Put clean engine oil on the thread of the shaft and on the nut face of the compressor wheel. Install the washer and nut (8). Use a universal joint and a socket of the correct size to tighten the nut. Tighten the nut to a torque of 120 ± 5 N·m (89 ± 3.7 lb ft).
27. Put clean engine oil on O-ring seal (9) and install it.
28. Place the cartridge group in a vise and use tooling (D) to check the shaft end play. The end play must be 0.110 ± 0.020 mm (.0043 ± .0008 in).
29. Use tooling (D) to check the runout of the shaft at the nut. The maximum runout allowed is 0.75 mm (.0295 in).
30. Put the cartridge group in tool (B) and install diffuser (7). Be sure the hole in the diffuser is over the locating pin.
31. Use tooling (A) and a hoist and install compressor housing (4). Install straps (6), the washers, and bolts (5). Tighten the bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
NOTE: Replace the used lock plates.
32. Install the cartridge group in turbine housing (3). Align the marks on the housings for correct branch positioning. Put 5P3931 Anti-Seize Compound on the threads of bolts (1). Install straps (2), the lock plates and bolts (1). Tighten the bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft). Close the short end of the lock plates around the bolt heads and the long end of the turbine clamp after final assembly.
33. Remove tooling (A).
End By:
a. install turbocharger