Usage:
start by:
remove turbocharger
1. Install turbocharger in tool group (A). Put marks on th three housings of the turbocharger for correct installation and alignment at assembly. Remove "V" clamp (2) and compressor housing (1).
2. Remove "V" clamp (3). Remove the cartridge housing (5) from the turbine housing (4).
3. Install tool (C) in tool (B) and put the cartridge assembly in tool (C) as shown. Use tool (D) to remove the nut that holds compressor wheel (6).
| NOTICE |
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When the nut is loosened, do not put a side force on the shaft. |
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The oil used to heat the compressor wheel must have a flash point (the temperature at which the oil will burn) above 400°F (204°C). |
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4. Install tool (H) on tool (E). Heat tool (E) to a temperature of 350°F (177°C). Install the cartridge assembly on tool (H) so that only the compressor wheel is in the oil. Heat the compressor wheel for no more than 10 minutes.
| NOTICE |
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Do not let the turbine wheel hit the bottom of the press. |
5. Install tool (H) on tool (G). Put the cartridge assembly in tool (H) as shown. Remove compressor wheel (6) with an arbor press and tool (F).
NOTE: Step 5 must be done before the compressor wheel becomes cooler.
6. Put the turbine wheel in tool (C). Remove seal ring (8) and shroud (7) from the shaft.
7. Bend the tabs of the locks from bolts (10) and remove the bolts and locks.
8. Remove backplate assembly (11) from the cartridge housing. Remove spacer (9) from backplate assembly (11). Remove the seal rings from spacer (9).
9. Remove the collar from behind backplate assembly (11).
10. Remove thrust bearing (13) and O-ring seal (12) from the cartridge housing.
11. Remove top bearing (14) and the washer from the cartridge housing. Put a long dye mark on the top face of bearing (14).
12. Use tool (J) and remove the two rings that hold top and bottom bearings in position. Remove the bottom bearing and washer. Put a short dye mark on the bearing.
NOTE: The dye marks are used for identification of the bearings when they are installed.
13. Use tool (J) and remove the last ring that holds the bottom bearing in position from the cartridge housing.
14. Check all the parts of the turbocharger for damage. If the parts have damage, use new parts for replacement. See SPECIAL INSTRUCTION FORM NO. SMHS6854 for TURBOCHARGER RECONDITIONING. Also see GUIDELINE FOR REUSABLE PARTS FORM NO. SEBF8018.
Assemble Turbocharger (Airesearch TV81)
1. Make sure that all of the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material.
2. Put clean engine oil on all parts of the cartridge assembly.
| NOTICE |
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Rings (1), (4) and (5) must be installed with the round edge of the rings toward the bearings. |
3. Install ring (4) in the cartridge housing with tool (A).
4. Install washer (3) and bearing (2) in the cartridge housing. Make sure the short dye mark on bearing (2) is up.
5. Install rings (1) and (5) in the cartridge housing with tool (A).
NOTE: Put 6V2055 High Vacuum Grease in the groove for seal ring (7) at assembly to one half or more of the depth of the groove all the way around.
6. Install tool (D) in tool (C). Install turbine shaft (6) in tool (D). Install seal ring (7) and shroud (8) on turbine shaft (6).
7. Install turbine shaft (6) in the cartridge housing.
| NOTICE |
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Make sure the seal ring on turbine shaft (6) is fitted correctly in the cartridge housing. |
8. Install washer (12), bearing (11) with the long dye mark up, thrust washer (10) with the three lubrication grooves up and O-ring seal (9) in the cartridge housing.
9. Install the seal rings on spacer (13). Install spacer (13) in backplate assembly (15). Make sure the chamfer end of spacer (13) is toward the inside of the cartridge assembly when the backplate assembly is installed.
10. Install collar (14) and backplate assembly (15) on the catridge assembly with the oil hole in the backplate assembly in alignment with the oil hole in the cartridge housing.
11. Install the locks and bolts (16) that hold backplate assembly (15) in position. Tighten the bolts to a torque of 90 ± 10 lb.in. (10.2 ± 1.1 N·m).
12. Use tool (B) to heat the compressor wheel in oil for no more than 10 minutes. The temperature of the oil must be 350°F (177°C).
13. Immediately after the compressor wheel is removed from the oil, put the wheel on the turbine shaft. Install the nut on the end of the shaft. Use a torque wrench and a universal socket of the correct size to tighten the nut to a torque of 150 lb.in. (17.0 N·m) as shown.
| NOTICE |
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Do not put a side force on the shaft when the nut is installed or removed. |
14. When the shaft is cool, remove the nut with tool (F). Check the face of the nut and the front face of the compressor wheel. Make sure they are clean and smooth. Put clean oil on the nut and install it on the shaft again. Use a torque wrench and a universal socket of the correct size and tighten the nut to a torque of 30 lb.in. (3.4 N·m). Put a mark across the nut and tighten it 90° more with tool (F).
15. Make sure the compressor wheel is clean and dry.
16. Put the cartridge housing in a vise as shown. Check the shaft end play with tool (E). The end play must be .003 to .010 in. (0.08 to 0.25 mm) (new). If the shaft end play is not the correct dimension, the inside parts of the center housing must be checked for too much wear. See TURBOCHARGER (AIRESEARCH TV81) in SPECIFICATIONS.
17. Install the turbine housing on tool group (G). Put the cartridge assembly in position in the turbine housing. Make sure the marks on the housings are in alignment with each other. Put 5P3931 Anti-Seize Compound on the threads of the "V" clamp that holds the cartridge assembly to the turbine housing. Install the "V" clamp and tighten the bolt to a torque of 120 ± 10 lb.in. (13.6 ± 1.1 N·m).
18. Install the compressor housing to the cartridge assembly. Install the "V" clamp that holds the compressor housing to the cartridge housing and tighten the bolt to a torque of 120 ± 10 lb.in. (13.6 ± 1.1 N·m).
end by:
a) install turbocharger