Usage:
Remove Turbocharger
start by:
a) remove air cleaner assembly
1. Remove exhaust elbow (3) and bracket (6).
2. Remove oil supply line (1).
3. Remove oil line (4).
4. Disconnect oil return line (5).
5. Remove bolt (2) and washer.
6. Fasten a hoist to turbocharger (7) and remove it from engine. Weight of turbocharger is 70 lb. (32 kg).
Install Turbocharger
1. Put turbocharger in place on engine.
2. Put 9M3710 Anti-Seize Compound on threads of bolts (5). Install bolts (5) and tighten nuts to 40 ± 5 lb. ft. (55 ± 7 N·m).
3. Install bolt (1) and washer.
4. Connect oil return line (4).
5. Install oil line (2).
6. Install oil supply line (3).
7. Install exhaust elbow (6) and bracket. Put 9M3710 Anti-Seize Compound on threads of bolts for bracket. Install bolts and tighten nuts to 40 ± 5 lb. ft. (55 ± 7 N·m).
Disassemble Turbocharger (Schwitzer Model 4HD)
start by:
a) remove turbocharger
1. Install turbocharger on tool group (A). Remove band clamp (1) and compressor housing (2).
2. Remove bolts (4), locks and cartridge assembly (3).
3. Remove nozzle ring (6) from turbine housing (5).
4. Put cartridge assembly in tool (B) and remove the nut that holds compressor wheel (7). Remove compressor wheel.
5. Remove turbine wheel (9) and shaft from cartridge housing. Remove seal rings (8) from shaft.
6. Remove snap ring (10) and plate (11).
7. Remove snap ring that holds insert (12) in housing. Remove insert (12) with tooling (C).
8. Remove sleeve (14) from insert (13) and remove seal rings from sleeve.
9. Remove deflector (15) and ring from housing.
10. Remove bearing (16), spacer (17), ring (18) and spacer (19).
11. Remove bearing (20) from housing.
12. Remove two snap rings (21) with tool (D). Remove other bearing from housing.
Assemble Turbocharger (Schwitzer Model 4HD)
1. Install two bearings (1) and snap rings in housing. Install snap rings with tool (A).
2. Install spacer (2), ring (3) and spacer (4).
3. Install bearing (7), ring (6) and deflector (5). Tighten bolts (11) to 60 lb. in. (6.8 N·m).
4. Install seal rings on sleeve (9) and install sleeve in insert (8).
5. Install O-ring (10), insert (8) and snap ring in housing.
6. Install plate (12) and snap ring.
7. Install seal rings on turbine shaft.
8. Install turbine and shaft (14) in housing (15). Put end of turbine in tool (B) and install shims (13).
9. Install compressor wheel (16) on shaft.
10. Install nut that holds compressor wheel on shaft. Tighten nut to 32 ± 2 lb. ft. (43 ± 3 N·m).
11. Check clearance between compressor wheel (16) and housing (15). Clearance must be .020 ± .002 in. (0.51 ± 0.05 mm). Add or remove shims to get correct clearance between compressor wheel and housing.
12. Install turbine housing (17) on tool group (C). Install nozzle (18) and cartridge assembly (19) in turbine housing. The flat surface of cartridge assembly that has large oil hole must be parallel with exhaust inlet (20) of turbine housing.
13. Put 9M3710 Anti-Seize Compound on the threads of bolts (21) and install the bolts and locks. Tighten bolts to 17 lb. ft. (23 N·m).
14. Install O-ring (23), compressor housing (22) and band clamp.
15. Install turbocharger on tool group (D) to put compressor housing at correct angle. Correct angle for compressor air outlet is 51°.
16. Tighten nut on band clamp to a torque of 120 ± 10 lb. in. (13.6 ± 1.1 N·m).
end by:
a) install turbocharger