Installation Procedure
| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A | 5P-3931 | Anti-Seize Compound | - |
| NOTICE |
|---|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
| NOTICE |
|---|
The alignment of the bellows is important. Improper alignment may lead to premature failure of the bellows. Misalignment can be identified by visually inspecting the convolutions for uniformity of compression. Inspect the bellows for damage prior to installation. If there is any damage to the convolutions, discard the bellows. Minor damage to the ends of the bellows may be repaired. However, if there is any difficulty in installation after the repair, discard the bellows. |
- Install a new seal (17) and backup ring (16) in bellows (18) .
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| Illustration 1 | g01076587 |
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| Illustration 2 | g01502594 |
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The ends of the bellows are very sharp. Injury could occur if the bellows are not handled properly. Handle the bellows by the convolutions. |
Note: Refer to Special Instruction, REHS1728, "Application Guideline for the Bellows" for additional information on handling the bellows.
- Install turbocharger gasket (19) on the exhaust manifold.
- Use a suitable lifting device in order to install turbocharger (14) on the exhaust manifold and in the bellows on the precooler. The weight of the turbocharger is approximately 25 kg (55 lb).
Note: If necessary, loosen clamp (13) and rotate the turbocharger housing in order to align the bellows for assembly.
- Apply Tooling (A) to the threads of the studs. Apply Tooling (A) to the mating surface of locknuts (12) . Install locknuts (12) . Tighten locknuts (12) in a numerical sequence to a torque of 54 ± 5 N·m (40 ± 4 lb ft). Refer to Illustration 2.
Note: Discard the locknuts after use. Use new locknuts for installation.
- Install clamp assembly (15) . Apply Tooling (A) to the threads of the clamp assembly and tighten to a torque of 9 ± 2 N·m (80 ± 18 lb in).
- If clamp assembly (13) was loosened, apply Tooling (A) to the threads of the clamp assembly and tighten to torque of 16 ± 1 N·m (142 ± 9 lb in).
- Connect hose assembly (11) (not shown).
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| Illustration 3 | g01076580 |
- Connect hose assembly (3) .
- Connect hose (8) .
- Install bellows (6) and duct (1) to the turbochargers.
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The ends of the bellows are very sharp. Injury could occur if the bellows are not handled properly. Handle the bellows by the convolutions. |
Note: Refer to Special Instruction, REHS1728, "Application Guideline for the Bellows" for additional information on handling the bellows.
- Install clamp assembly (7) . Apply Tooling (A) to the threads of the clamp assembly and tighten to a torque of 12 ± 4 N·m (106 ± 35 lb in).
- Install clamp assembly (2) . Apply Tooling (A) to the threads of the clamp assembly and tighten to a torque of 12 ± 4 N·m (106 ± 35 lb in).
- Install bellows (10) and duct (5) on the turbochargers.
|
The ends of the bellows are very sharp. Injury could occur if the bellows are not handled properly. Handle the bellows by the convolutions. |
Note: Refer to Special Instruction, REHS1728, "Application Guideline for the Bellows" for additional information on handling the bellows.
- Install clamp assembly (9) . Apply Tooling (A) to the threads of the clamp assembly and tighten to a torque of 12 ± 4 N·m (106 ± 35 lb in).
- Install clamp assembly (4) . Apply Tooling (A) to the threads of the clamp assembly and tighten to a torque of 12 ± 4 N·m (106 ± 35 lb in).