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| Illustration 1 | g00484300 |
(1) Bolt
-
Lubricate the bolt threads with 5P-3931 Anti-Seize Compound .
- Torque ... 60 ± 12 N·m (44 ± 9 lb ft)
(2) Bolt
-
Lubricate the bolt threads with 5P-3931 Anti-Seize Compound .
- Torque ... 105 ± 20 N·m (77 ± 15 lb ft)
(3) Housing
- Bore in housing for shaft bearings ... 25.845 ± 0.013 mm (1.0175 ± 0.0005 inch)
- OD of shaft bearings ... 25.898 ± 0.013 mm (1.0196 ± 0.0005 inch)
- ID of in-line shaft bearings ... 19.806 ± 0.013 mm (0.7798 ± 0.0005 inch)
- Diameter of shaft ... 19.500 ± 0.013 mm (0.7677 ±0.0005 inch)
- OD of shaft bearings ... 25.898 ± 0.013 mm (1.0196 ± 0.0005 inch)
(4) Adjustable rod
(5) Bolt
-
Lubricate the bolt threads with 5P-3931 Anti-Seize Compound .
- Torque ... 47 ± 9 N·m (35 ± 7 lb ft)
(6) Thrust washer
- Thickness of thrust washer ... 6.00 ± 0.08 mm (0.236 ± 0.003 inch)
(7) Assemble the cross shaft with the end that is stamped "W/G END" toward the housing of the wastegate.
(8) Plate and mounting bolts
(9) Mounting bolts for plate
- Torque ... 14 ± 3 N·m (10 ± 2 lb ft)
(10) Actuator
(11) Outlet port
Note: Assemble the actuator so the inlet port and the outlet port are aligned. This is shown in Illustration 1. The ports on the actuator are stamped "Inlet" and "Outlet".
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| Illustration 2 | g01004547 |
Adjustable rod linkage and rod linkage
(12) Nuts
- Torque ... 25 ± 6 N·m (18 ± 4 lb ft)
Assemble the lever on the cross shaft. Install the lever on the same side as the actuator. Use the woodruff key to assemble the lever. Assemble the linkage on the actuator. Check the distance between the rod end and the clevis when the actuator is in the extended position.
Distance between the rod end and the clevis ... 242 ± 1.0 mm (9.5275 ± 0.0394 inch)
Note: A final adjustment of the linkage is required. The adjustment of the linkage ensures that the plate does not contact the housing. In the closed position, contact the housing with the plate. Make sure that the actuator is fully extended. Shorten the length of the upper connecting rod by one turn (360 degrees). Lock the connecting rod in place.
(A) Angle for the lever in the closed position ... 44.3 degrees
(B) Angle for the lever in the closed position ... 29.6 degrees
(13) Nuts
- Torque ... 25 ± 6 N·m (18 ± 4 lb ft)
Assemble the plate to the shaft. Assemble the levers to the shaft and to the cross shaft. Use the woodruff keys to provide the proper orientation. Assemble and adjust the upper connecting rod to the correct distance.
Distance between the rod ends of the upper connecting rod ... 134.9 ± 1.0 mm (5.31 ± 0.04 inch)
(C) Angle for the lever in the closed position ... 45 degrees
(D) Angle for the lever in the closed position ... 44.3 degrees
(E) Angle for the lever in the closed position ... 30 degrees
(F) Angle for the lever in the closed position ... 29.6 degrees