Usage:
START BY:
a. remove turbocharger
1. Put the turbocharger in position on tooling (A).
NOTE: Put alignment marks on the compressor and exhaust housings as to their location on the cartridge so they can be installed in the same position.
2. Bend the tabs on the locks away from the bolts.
3. Remove bolts (2), locks (1) and compressor housing (3).
4. Bend the tabs on the locks away from the bolts. Remove bolts (5), the locks and cartridge assembly (4) from exhaust housing (6).
5. Put the cartridge assembly in position in tooling (B).
| NOTICE |
|---|
Do not put a side force on the shaft and wheel assembly when the nut is loosened. |
6. Remove nut (7) from the shaft.
| NOTICE |
|---|
Do not let shaft assembly (9) fall when it is pushed out of the cartridge assembly. |
7. Use a press to push shaft assembly (9) out of the cartridge assembly.
8. Remove wheel (8) from the cartridge.
9. Remove seal ring (11) from shaft assembly (9).
10. Remove shroud (10) from the shaft.
NOTE: Put alignment marks on the cartridge and backplate assembly (14) as to the location of the backplate on the cartridge so it can be installed in its original position.
11. Bend the tabs on the locks away from the bolts.
12. Remove bolts (13) and locks (12).
13. Remove the cartridge from backplate assembly (14).
14. Remove bearing (15) and collar (16) as a unit from the backplate assembly.
15. Remove bearing (15) from collar (16).
16. Remove seal ring (17) from collar (16).
17. Remove spring (18) from the backplate assembly.
18. Remove seal ring (19) from the cartridge housing.
19. Remove snap ring (21), bearing (20) and snap ring (22) from the cartridge housing.
20. Turn the cartridge housing over, and remove snap ring (24), bearing (23) and snap ring (25).
NOTE: For more information on turbochargers, see Analyzing Turbocharger Failure, Form No. FEG45138, Guideline For Reusable Parts - Turbochargers, Form No. SEBF8018 and Guideline For Reusable Parts - Specifications For Reusable Turbocharger Components, Form No. SEBF8019.
Assemble Turbocharger (T04B)
1. Clean all parts thoroughly before they are assembled. Put clean engine oil on all parts.
2. Install snap ring (2), bearing (3) and snap ring (1) in the cartridge housing.
3. Turn the cartridge housing over, and install snap ring (5), bearing (6) and snap ring (4).
4. Put seal ring (7) in position on the cartridge housing.
5. Put seal ring (8) in position on collar (9).
NOTE: Bearing (10) must be installed on the collar with the side that has a groove up as shown.
6. Put bearing (10) in position on collar (9).
7. Put bearing (10) and the collar in position on the cartridge housing as a unit. Align the holes in the bearing with dowels (11).
8. Put spring (12) in position in backplate (13).
9. Put shaft assembly (14) in position on tooling (A).
10. Fill the groove in the shaft with 6V2055 High Vacuum Grease.
11. Put seal ring (16) in position on the shaft assembly.
12. Install shroud (15) as shown.
13. Put the cartridge housing in position on shaft assembly (14).
14. Install the backplate in its original position, locks (18) and bolts (17). Tighten the bolts to a torque of 8.5 - 10.2 N·m (75 - 90 lb.in.).
15. Bend the tabs on locks (18) up against the bolts.
16. Put compressor wheel (19) in position, and install the nut.
| NOTICE |
|---|
Do not put a side force on the shaft and wheel assembly when the nut is tightened. |
17. Put a small amount of oil on the turbine shaft threads and the compressor wheel face that makes contact with the nut. Install the nut, and tighten it to a torque of 2.25 N·m (20 lb.in.). Tighten the nut an additional 110°.
18. Remove the nut, and put 6V1541 Quick Cure Primer on the shaft and nut.
19. Put 9S3265 Retaining Compound on the threads of the shaft and nut. Tighten the nut to a torque of 2.25 N·m (20 lb.in.). Tighten the nut an additional 110°.
20. Put cartridge assembly (20) in a vise as shown. Make sure the soft (brass) jaws are used.
21. Install tooling (C) on the cartridge assembly to check end play. The end play must be 0.03 - 0.10 mm (.001 - .004 in.).
22. Put cartridge assembly (20) in its original position in turbine housing (21).
23. Put 5P3931 Anti-Seize Compound on bolts (23).
24. Put locks (22) in position, and install the bolts. Tighten the bolts to a torque of 13 ± 1.7 N·m (115 ± 15 lb.in.). Bend the tabs on the locks against the holes.
25. Put compressor housing (24) in its original position on the cartridge assembly.
26. Put locks (25) in position, and install bolts (26). Tighten the bolts to a torque of 13 ± 1.7 N·m (115 ± 15 lb.in.). Bend the tabs on the locks against the bolts.
27. Remove the turbocharger from tooling (B).
END BY:
a. install turbocharger