Usage:
NOTE: Removal is shown for one side only. The procedure is the same for both sides.
1. Remove the pipe to the aftercooler housing.
2. Disconnect turbocharger drain lines (5) and (6).
3. Disconnect turbocharger oil supply lines (2) and (3).
4. Bend the tabs down. Remove two bolts (4).
5. Remove two clamps (1). Remove the tube.
6. Use two people or attach a hoist to turbocharger (7). The weight of the turbocharger is 29.5 kg (65 lb).
7. Remove four bolts (9). Remove the turbocharger.
8. Use two people or attach a hoist to turbocharger (8). The weight of the turbocharger is 29.5 kg (65 lb).
9. Remove four bolts (10). Remove the turbocharger.
Install Turbochargers (Engine With Four Turbochargers)
NOTE: Installation is shown for one side only. The procedure is the same for both sides.
| NOTICE |
|---|
Make sure the 2P-2333 Manifold Sealer does not get on the inside of the pipes. Damage to the turbocharger could be the result if the manifold sealer gets on the impeller on the turbocharger. |
1. Put 2P-2333 Manifold Sealer on the male ends of turbochargers (8).
2. Use a hoist or two people to install turbocharger (8).
NOTE: Use a new gasket between turbocharger (8) and the elbow.
3. Apply 5P-3931 Anti-Seize Compound to four bolts (10). Install the bolts.
4. Put 2P-2333 Manifold Sealer on the male ends of turbocharger (7).
5. Use a hoist or two people to install turbocharger (7).
NOTE: Use a new gasket between turbocharger (7) and the elbow.
6. Apply 5P-3931 Anti-Seize Compound to four bolts (9). Install the bolts.
7. Lubricate the O-ring seals for the pipe with glycerin.
8. Install the pipe with two clamps (1). Tighten the wrap around clamp to a torque of 7.0 ± 1.5 N·m (5 ± 1 lb ft). Tighten the bolts on the half clamp to standard torque.
9. Install two bolts (4). Bend the tabs down.
10. Install the pipe to the aftercooler housing.
11. Use new gaskets and attach oil drain lines (5) and (6).
12. Use new gaskets and attach oil supply lines (2) and (3).
Disassemble Turbocharger (S3B)
Start By:
a. remove turbocharger
1. Install the turbocharger on Tool (A). Put alignment marks on the three housings of the turbocharger for correct installation. Remove "V" clamp (2) and compressor housing (1).
2. Remove "V" clamp (3). Remove cartridge housing (5) from turbine housing (4).
| NOTICE |
|---|
When the nut is loosened, do not put a side force on the shaft. This can result in a bent shaft. |
3. Install Tool (C) in Tool (B). Put the cartridge assembly in Tool (C) as shown. Use Tool (D) to remove the nut that holds compressor wheel (6).
4. Put the cartridge assembly in Tool (E) and use a press (if necessary) to remove compressor wheel (6) from the turbine wheel and shaft assembly. Do not let the turbine wheel and shaft assembly fall during removal of the compressor wheel from the turbine wheel and shaft.
5. Remove seal ring (7) and shroud (8) from turbine wheel and shaft assembly (9).
6. Bend the tabs of the locks from bolts (10) and remove the bolts and locks.
7. Remove backplate assembly (11) from the cartridge housing.
8. Remove spacer (12) from backplate assembly (11). Remove seal rings (13) from spacer (12).
9. Remove collar (14), thrust bearing (15) and O-ring seal (16) from the cartridge housing.
10. Remove top bearing (17) and the washer from the top cartridge housing. Put a long dye mark on the top face of bearing (17).
11. Use Tool (F) and remove the two rings that hold the top and bottom bearings in position. Remove the bottom bearings and washer. Put a short dye mark on the bearing.
NOTE: The dye marks are used for identification of the bearings when they are installed.
12. Use Tool (F) and remove the last ring that holds the bottom bearing in position on the cartridge housing.
13. Check all the parts of the turbocharger for damage. If the parts are damaged, use new parts for replacement. See Special Instruction Form No. SMHS6854 for Turbocharger Reconditioning. Also see Guidelines For Reusable Parts, Form No. SEBF8018.
Assemble Turbocharger (S3B)
1. Make sure that all of the oil passages in the turbocharger cartridge housing are clean and free of dirt and debris.
2. Put clean engine oil on all parts of the cartridge assembly.
| NOTICE |
|---|
Rings (18), (21) and (22) must be installed with the round edge of the outside diameter of the rings toward the bearings. |
3. Install ring (21) in the cartridge housing with Tool (F).
4. Install washer (19) and bearing (20) in the cartridge housing. Make sure the short dye mark on bearing (20) is up.
5. Install rings (18) and (22) in the cartridge housing with Tool (F).
6. Install washer (23).
7. Install bearing (17) with the long dye mark up.
8. Install bearing (15). Align the pins in the cartridge with the holes in the bearing. Be sure the three lubrication grooves are facing up as shown.
9. Install collar (14) with the small diameter toward bearing (15). Put O-ring (16) in position.
NOTE: Put 6V-2055 High Vacuum Grease in the grooves of spacer (12) to one half or more of the depth of the grooves all the way around.
10. Use Tool (B) to install seal rings (13) on to spacer (12).
11. Install spacer (12) into backplate (11). Be sure the chamfered end of spacer (12) is toward the inside of the cartridge assembly when the backplate assembly is installed.
12. Install backplate assembly (11) on the cartridge assembly with the oil hole in the backplate assembly in alignment with the oil hole in the cartridge housing.
13. Install locks and bolts (10) that hold backplate assembly (11) in position. Tighten the bolts to a torque of 10 ± 1 N·m (90 ± 9 lb in).
NOTE: Put 6V-2055 High Vacuum Grease in the groove for seal ring (7) at assembly to one half or more of the depth of the groove all the way around.
14. Use Tool (G) to install shroud (8) and seal ring (7) onto turbine wheel and shaft assembly (9).
15. Position the cartridge assembly on Tool (F) and install turbine wheel and shaft assembly (9) into the cartridge assembly.
NOTE: Make sure the seal ring on the turbine wheel and shaft assembly (9) is fitted correctly in the cartridge housing.
16. Install Tool (C) in Tool (B) and place the cartridge assembly in Tool (C). Install compressor wheel (6) on the shaft.
| NOTICE |
|---|
Do not put side force on the shaft when the nut that holds the compressor wheel in position is tightened. |
17. Put a small amount of clean engine oil on the turbine shaft threads and compressor wheel face that makescontact with the nut. install the nut and tighten it to a torque of 17 N·m (13 lb ft) to push compressor wheel (6) on the shaft. Loosen the nut and tighten it again to a torque of 3.5 N·m (30 lb in). Tighten the nut an additional 120 degrees of a turn.
18. Remove the nut from the turbine shaft and put 6V-1541 Quick Cure Primer on the turbine shaft and nut.
19. Put 9S-3265 Retaining Compound on the threads of the shaft and nut. Install the nut and tighten it to a torque of 3.5 N·m (30 lb in). Tighten the nut an additional 120 degrees of a turn.
20. Install turbine housing (4) on Tool (A) as shown. Put clamp (3) in the cartridge and put the cartridge in position on the housing. Make sure the marks on the housing and cartridge are in alignment. Move clamp (3) in position and tighten the nut to a torque of 18 ± 3 N·m (13 ± 2 lb ft). Tap the clamp lightly with a soft faced hammer and tighten the clamp nut again to the same torque value.
21. Place Tool (E) in position on the backplate as shown. Check the shaft end play. The shaft end play must be 0.08 mm (.003 in). The shaft end play must not exceed 0.25 mm (.010 in).
22. Install clamp (2) and compressor housing (1) on the cartridge in the correct position. Move clamp (2) into position and tighten the nut to a torque of 18 ± 3 N·m (13 ± 2 lb ft). Tap the clamp lightly with a soft faced hammer and tighten the clamp nut again to the same torque value.
End By:
a. install turbocharger
Disassemble Turbocharger (TV81)
Start By:
a. remove turbocharger
1. Install turbocharger in Tool group (A). Put marks on the three housings of the turbocharger for correct installation and alignment at assembly. Remove "V" clamp (2) and compressor housing (1).
2. Remove "V" clamp (5). Remove the cartridge housing (3) from the turbine housing (4).
| NOTICE |
|---|
When the nut is loosened, do not put a side force on the shaft. |
3. Install the cartridge assembly in a vise as shown. Remove the nut that holds compressor wheel (6).
4. Remove compressor wheel (6) with a press.
5. Remove seal ring (8) and shroud (7) from the shaft.
6. Bend the tabs of the locks from bolts (10) and remove the bolts and locks.
7. Remove backplate assembly (11) from the cartridge housing. Remove spacer (9) from backplate assembly (11). Remove the seal rings from spacer (9).
9. Remove the collar from behind backplate assembly (11).
10. Remove thrust bearing (13) and O-ring seal (12) from the cartridge housing.
11. Remove top bearing (14) and the washer from the cartridge housing. Put a long dye mark on the top face of bearing (14).
12. Remove the two rings that hold top and bottom bearings in position. Remove the bottom bearing and washer. Put a short dye mark on the bearing.
NOTE: The dye marks are used for identification of the bearings when they are installed.
13. Remove the last ring that holds the bottom bearing in position from the cartridge housing.
14. Check all the parts of the turbocharger for damage. If the parts have damage, use new parts for replacement. See Special Instruction, Form No. SMHS6854, for Turbocharger Reconditioning. Also, see Guideline for Reusable Parts, Form No. SEBF8018-01.
Assemble Turbocharger (TV81)
1. Make sure that all of the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material.
2. Put clean engine oil on all parts of the cartridge assembly.
| NOTICE |
|---|
Rings (15), (18) and (19) must be installed with the round edge of the rings toward the bearings. |
3. Install washer (17) and bearing (16) in the cartridge housing. Make sure the short dye mark on bearing (16) is up.
4. Install rings (15) and (19) in the cartridge housing.
NOTE: Put 4L-7464 Silicone Grease in the groove for seal ring (8) at assembly to one half or more of the depth of the groove all the way around.
5. Install Tool (D) in Tool (C). Install turbine shaft (20) in Tool (D). Install seal ring (8) and shroud (7) on turbine shaft (20).
6. Install turbine shaft (20) in the cartridge housing.
| NOTICE |
|---|
Make sure the seal ring on turbine shaft (20) is fitted correctly in the cartridge housing. |
7. Install the washer, bearing (14) with the long dye mark up, thrust washer (13) with the three lubrication grooves up and O-ring seal (12) in the cartridge housing.
8. Install the seal rings on spacer (9). Install spacer (9) in backplate assembly (11). Make sure the chamfer end of spacer (9) is toward the inside of the cartridge assembly when the backplate assembly is installed.
9. Install collar (21) and backplate assembly (11) on the cartridge assembly with the oil hole in the backplate assembly in alignment with the oil hole in the cartridge housing.
10. Install the locks and bolts (10) that hold backplate assembly (11) in position. Tighten the bolts to a torque of 10.2 ± 1.1 N·m (90 ± 10 lb in).
11. Use the following procedure to install the impeller on the shaft.
a. Put impeller on shaft.
b. Put a small amount of clean oil on the threads and impeller face that will be under the nut.
NOTE: Do not bend or add stress to the shaft when the nut is loosened or tightened.
c. Tighten the nut to a torque of 14.1 to 17.0 N·m (125 to 150 lb in).
d. Loosen the nut on the shaft.
e. Tighten the nut to 3.5 N·m (30 lb in).
f. Tighten the nut 120 degrees more.
g. Remove the nut from the shaft.
h. Use 6V-1541 Quick Cure Primer on the threads of the shaft and the nut.
j. Put 9S-3265 Retaining Compound on the threads of the shaft and the nut.
k. Install and tighten the nut to 3.5 N·m (30 lb in).
l. Tighten the nut 120 degrees more.
12. Put the cartridge housing in a vise as shown. Check the shaft end play with Tool (E). The end play must be 0.08 to 0.25 mm (.003 to .010 in). If the shaft end play is not the correct dimension, the inside parts of the center housing must be checked for too much wear.
NOTE: For more information, see the topic "Turbocharger" in Specifications Manual, Form No. SENR4651.
Typical Example.
13. Install the turbine housing on Tool (G). Put the cartridge assembly in position in the turbine housing. Make sure the marks on the housings are in alignment with each other. Put 5P-3931 Anti-Seize Compound on the threads of the "V" clamp (5) that holds the cartridge assembly to the turbine housing. Install "V" clamp (and tighten the bolt to a torque of 14.0 ± 1.5 N·m (124 ± 13 lb in). Lightly hit all around clamp with a soft faced hammer and again tighten to a torque of 14.0 ± 1.5 N·m (124 ± 13 lb in).
14. Install the compressor housing to the cartridge assembly. Install "V" clamp (2) that holds the compressor housing to the cartridge housing and tighten the bolt to a torque of 14.0 ± 1.5 N·m (124 ± 13 lb in). Install "V" clamp (and tighten the bolt to a torque of 14.0 ± 1.5 N·m (124 ± 13 lb in). Lightly tap the clamp all around with a soft faced hammer and tighten again to a torque of 14.0 ± 1.5 N·m (124 ± 13 lb in).
End By:
a. install turbocharger
Disassemble Turbochargers (TV92)
Start By:
a. remove turbochargers
1. Put the turbocharger in position on Tool (A) as shown. Put marks on the three housings of the turbocharger for correct installation and alignment at assembly.
2. Loosen clamp (2) and remove compressor housing (1) and the clamp from the cartridge assembly.
3. Bend the tabs on locks (4) from the bolts. Remove the bolts, locks (4) and the clamps that hold cartridge housing (3) in turbine housing (5).
4. Remove cartridge housing (3) from turbine housing (5).
| NOTICE |
|---|
To prevent a bend shaft, do not put a side force on the turbine shaft when the compressor wheel nut is loosened. |
5. Put the end of the turbine shaft in Tool (B). Use a universal joint and socket of the correct size to remove the nut that holds compressor wheel (6) on the turbine shaft.
6. Use a press and push the turbine shaft out of compressor wheel (6) and the cartridge housing. Remove compressor wheel (6) from the cartridge housing.
7. Remove seal ring (8) and shroud (9) from turbine shaft (7).
8. Bend the tabs of the locks from bolts (10) and remove the bolts.
9. Remove backplate assembly (11) from the cartridge housing. Make a note of the position of the oil holes in the backplate assembly and cartridge housing for correct alignment at assembly.
10. From the opposite side of backplate (11) that is shown, push spacer (12) out of its bore.
11. Remove seal rings (13) from spacer (12).
12. Remove thrust collar (14) and seal ring (15) from the cartridge housing.
13. Remove thrust bearing (16) from the cartridge housing.
NOTE: If the bearings are to be used again, put identification on them as to their location for correct assembly.
14. Remove bearing (17) from the cartridge housing.
15. Remove washer (18) from the cartridge housing.
16. Use Tool (C) and remove snap rings (19) and (20) from the cartridge housing.
17. Remove bearing (21) and washer (22) from the cartridge housing.
18. If necessary, use Tool (C) and compress the end snap ring and push it out of the bearing bore toward the compressor end of the cartridge housing to remove it.
Assemble Turbochargers (TV92)
1. Make sure all of the oil passages in the turbocharger cartridge housing, backplate assembly and bearings are clean and free of dirt and foreign material.
2. Put clean engine oil on all parts of the cartridge at assembly.
NOTE: Make sure the round edge of the snap rings are toward the bearings when the snap rings are installed.
3. Use Tool (A) and install snap ring (23) in the turbine end of the cartridge housing.
4. Install washer (22) and bearing (21). Use Tool (A) to install snap ring (20) to hold the washer and bearing in position.
5. Use Tool (A) and install snap ring (19) in the cartridge housing.
6. Install washer (18) and bearing (17) in the cartridge housing until washer (18) makes contact with snap ring (19).
7. Install thrust bearing (16) over the dowels in the cartridge housing. Make sure the grooves in bearing (16) are toward the outside as shown.
8. Install seal ring (15) in the groove of the cartridge housing.
9. Put thrust collar (14) in position on the thrust bearing with the counterbore for the spacer up.
10. Install seal ring (13) on spacer (12) so the gaps in the rings are 180 degrees apart.
11. Install spacer (12) in backplate assembly (11).
12. Make sure oil passage (24) in the cartridge housing and oil passage (25) in the backplate assembly are in alignment. Put backplate assembly (11) in position on the cartridge housing. Make sure the spacer fits correctly in the counterbore of the thrust collar.
13. Install the locks and bolts to hold backplate assembly (11) to the cartridge housing. Tighten the bolts to a torque of 40 ± 2 N·m (30 ± 1 lb ft) and bend the tabs of the locks on the bolts.
14. Put the turbine shaft in position in Tool (B). Put 6V-2055 High Vacuum Grease in the groove for seal ring (8). 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 (8) and shroud (9) on the turbine shaft.
15. Install the cartridge housing on the turbine shaft while spacer (12) is held in position. Make sure the seal ring on the turbine shaft is fitted correctly in the cartridge housing.
16. Use the following procedure to install the impeller on the shaft.
a. Put the impeller on the shaft.
b. Put a small amount of clean oil on the threads and impeller face that will be under the nut.
NOTE: Do not bend or add stress to the shaft when the nut is loosened or tightened.
c. Tighten the nut to a torque of 31 N·m (23 lb ft).
d. Loosen the nut on the shaft.
e. Tighten the nut to a torque of 5 N·m (50 lb in).
f. Tighten the nut 135 degrees more.
g. Remove the nut from the shaft.
h. Use 6V-1541 Quick Cure Primer on the threads of the shaft and the nut.
j. Put 9S-3265 Retaining Compound on the threads of the shaft and the nut.
k. Install and tighten the nut to 5 N·m (50 lb in).
l. Tighten the nut 135 degrees more.
17. Put the cartridge housing in a vise as shown. Check the shaft end play with Tool (C). The shaft end play must be 0.165 ± 0.063 mm (.0065 ± .0025 in).
18. Install turbine housing (5) on Tool (D) as shown. Put the cartridge in position in housing (5). Make sure the marks on the housing and cartridge are in alignment.
19. Put 5P-3931 Anti-Seize Compound on the threads of the bolts and install the clamps, locks (4) and the bolts to hold the cartridge in position. Tighten the bolts to a torque of 40 ± 2 N·m (30 ± 1 lb ft) and bend the tabs of the locks on the bolts.
20. Install clamp (2) and compressor housing (1) on the cartridge in the correct position. Move clamp (2) into position and tighten the nut to a torque of 14 ± 1 N·m (10 ± 1 lb ft). Lightly tap the clamp all around with a soft faced hammer and again tighten the clamp nut to the same torque value.
End By:
a. install turbochargers