Usage:
Remove And Install Turbochargers
start by:
a) remove turbocharger heat shield (if so equipped)
b) remove air cleaner housings
b) remove air cleaner housings
TYPICAL EXAMPLE
1. Loosen clamp (1) that holds the coupling to the exhaust elbow and remove shield (3). (Marine Engines only).
2. Remove turbocharger oil supply line (2).
TYPICAL EXAMPLE
3. Remove turbocharger oil return line (5). Remove four bolts (4) that fasten the turbocharger to the exhaust manifold.
TYPICAL EXAMPLE
4. Loosen clamp (6) that fastens the elbow to the aftercooler.
TYPICAL EXAMPLE
5. Remove the turbocharger from the engine. The turbocharger weighs 42 lb. (19 kg).
6. Put the turbocharger in position on the engine and install and tighten clamp (6).
7. Put 5P3931 Anti-Seize Compound on the threads of four bolts (4). Install the bolts and tighten to a torque of 40 ± 4 lb.ft. (55 ± 5 N·m). Install new gasket and turbocharger oil return line (5).
8. Install new gasket and turbocharger oil supply line (2).
9. Install shield (3) and clamp (1) (Marine Engines only).
end by:
a) install turbocharger heat shield (if so equipped)
b) install air cleaner housings
Disassemble Turbocharger
start by:
a) remove turbocharger
1. Put the turbocharger in position on tool (A).
2. Put a mark on the compressor cover and housings for installation purposes.
3. Remove "V" clamp (2) and remove compressor cover (1).
4. Remove "V" clamp (3) and remove shaft housing from turbine housing (4).
| NOTICE |
|---|
When the nut is loosened do not put a side force on the shaft. |
5. Put shaft housing in tool (B). Remove nut and compressor wheel (5) from the shaft.
6. Remove shaft housing from tool (B) and remove turbine wheel (7) and shaft from housing.
7. Remove seal ring (6) from the turbine wheel.
8. Remove snap ring and insert (8) from the housing.
9. Push the sleeve (9) out of the insert. Remove the two seal rings from the sleeve.
10. Remove deflector (10), ring (15), sleeve (11), bearing (12), ring (16), snap ring (13), bearing (17) and snap ring (14) from the housing. Remove snap rings (13) and (14) with tool (C).
NOTE: Check the oil hole in bearing (12). If the oil hole is not open this will cause a bearing failure.
11. Turn the housing around and remove snap ring (18) and shroud (22).
12. Remove snap ring (19), sleeve (20), bearing (21), and snap ring (23). Remove the two snap rings with tool (C).
13. Inspect all parts and install new parts as needed.
Assemble Turbocharger
1. Make sure all oil passages are open and clean. Put clean engine oil on all parts before assembly.
2. Install snap ring (4), bearing (3), sleeve (2) and snap ring (1). Install the two snap rings with tool (A).
NOTE: Install the snap rings with the round side toward the bearing.
3. Install shroud (5) on the housing. Turn the shroud to make sure it is down on the housing even. The high part (web) (6) on shroud, will keep the shroud from turning on the housing after assembly.
4. Install snap ring that holds the shroud in place.
5. Install the bearing and two snap rings in the compressor end of the housing. Install the snap rings with tool (A).
NOTE: Install the snap rings with the round side toward the bearing.
6. Put 6V2055 High Vacuum Grease in the groove for seal ring (7). 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 (7) on the shaft. Install turbine wheel (8) and shaft in the housing.
7. Put housing in position on tool (B).
| NOTICE |
|---|
The oil hole in bearing (11) must be open and clean. |
8. Install ring (13), bearing (11), sleeve (12), ring (10) and deflector (9) in the housing.
9. Install the seal rings on sleeve (15). Install sleeve in insert (14).
10. Install insert in the housing and install snap ring (17).
11. Install compressor wheel (16) on shaft.
| NOTICE |
|---|
When nut is tightened do not put a side force on the shaft. |
12. Put clean engine oil on the threads of the shaft. Install the nut (18) and tighten to the torque given in the SPECIFICATIONS for the specific turbocharger model.
13. Install shaft housing into the turbine housing. Put 5P3931 Anti-Seize Compound on the threads of the bolts that hold "V" clamp (21) in position. Install the "V" clamp and tighten the clamp to a torque of 10 ± 2 lb.ft. (14 ± 3 N·m).
14. Install compressor cover (19) and "V" clamp (20). Tighten "V" clamp to a torque of 10 ± 2 lb.ft. (14 ± 3 N·m).
end by:
a) install turbocharger