Usage:
Start by:
a. remove air filter
1. Remove two hose clamps (1) and pipe assembly (2) from the turbocharger exhaust tube.
2. Install a strap around turbocharger exhaust tube (4) and remove five bolts (3). Remove turbocharger exhaust tube (4). Exhaust tube (4) weighs 24 kg (54 lb).
3. Remove two bolts (5). Loosen hose clamp (7) and remove air filter housing (6).
4. Loosen three hose clamps (8) and remove the two water line hose ends from the turbocharger.
5. Remove two bolts (10). Remove oil supply tube (9).
6. Remove two bolts (12). Remove oil filler tube (11).
7. Remove four lock nuts (13). Remove turbocharger (14).
8. Loosen the V-band clamps and remove the compressor and turbine housings from the turbocharger cartridge.
NOTE: Place alignment marks on the turbocharger cartridge and the compressor and turbine housings. Alignment marks will be used during assembly.
NOTE: Turbocharger is serviceable at cartridge level only, or replace the complete turbocharger. Internal parts are not serviced.
NOTE: The following steps are for the installation of the turbocharger.
| NOTICE |
|---|
Do not over tighten the turbocharger V-band clamps. |
9. Install the compressor and turbine housings to the turbocharger cartridge. Tighten the V-band clamps that hold the compressor and turbine housings to the turbocharger cartridge to a torque of 13.5 ± 0.1 N·m (119.00 ± 1.00 lb in). Tap the clamps lightly all around and tighten the V-band clamps again to 13.5 ± 0.1 N·m (119.00 ± 1.00 lb in).
10. Apply 5P-3931 Anti-Seize Compound on the threads of the turbocharger mounting studs.
11. Check the condition of the gasket used between the turbocharger and the exhaust manifold. If the gasket is damaged, use a new part for replacement.
12. Put the gasket and turbocharger in position on the exhaust manifold. Install four locknuts (13) that hold it. Tighten the locknuts to a torque of 54 ± 5 N·m (40 ± 4 lb ft).
13. Check the condition of the gaskets used between the turbocharger and the oil supply and oil drain tube assemblies. If the gaskets are damaged, use new parts for replacement.
14. Install oil filter tube (11) and two bolts (12).
15. Install oil supply tube (9) and two bolts (10).
16. Install two water line hose ends on the turbocharger. Install and tighten three hose clamps (8).
17. Install air filter housing (6). Install and tighten hose clamp (7). Install two bolts (5).
18. Position turbocharger exhaust tube (4) and install five bolts (3). Exhaust tube (4) weighs approximately 24 kg (54 lb).
19. Install pipe assembly (2) to the turbocharger exhaust tube. Install and tighten two hose clamps (1).
End by:
a. install air filter