Usage:
(1) End play for shaft (new) ... 0.114 ± 0.038 mm (.0045 ± .0015 in)
Maximum permissible end play (worn) ... 0.20 mm (.008 in)
(2) Thickness of thrust bearing (where thrust rings contact bearing) ... 5.36 ± 0.03 mm (.211 ± .001 in)
(3) Tighten both band clamps with procedure that follows:
a Tighten to ... 14 ± 1.1 N·m (125 ± 10 lb in)
b. Tap (hit) clamp lightly all around.
c. Tighten again to ... 14 ± 1.1 N·m (125 ± 10 lb in)
| NOTICE |
|---|
Do not overtighten the clamps. |
(4) Diameter of shaft (new) ... 15.997 to 16.005 mm (.6298 to .6301 in)
Bore in the bearing (new) ... 16.035 to 16.043 mm (.6313 to .6316 in)
Maximum permissible clearance between bearing and shaft (worn) ... 0.05 mm (.002 in)
(5) Maximum permissible gap of oil seal ring, measured in bore of housing ... 0.25 mm (.010 in)
(6) Install the compressor wheel (at room temperature) as follows:
a. See Compressor Wheel Clearance for the correct shim thickness to use.
b. Put compressor wheel on the shaft.
c. Put a small amount of clean engine oil on the threads.
d. Tighten the nut to 14 to 17 N·m (125 to 150 lb in).
| NOTICE |
|---|
Do not bend or add stress to the shaft when nut is loosened or tightened. |
e. Remove nut from shaft and apply 6V1541 Quick Cure Primer on the threads of the shaft and nut followed by application of 9S3265 Retaining Compound.
f. Tighten nut to 4 N·m (30 lb in).
g. Tighten nut more 90° rotation.
(7) Shims. See Compressor Wheel Clearance for the correct shim thickness to use.
(8) Thickness of each thrust ring ... 2.553 ± 0.013 mm (.1005 ± .0005 in)
(9) Bore in housing (new) ... 24.994 to 25.006 mm (.9840 to .9845 in)
Outside diameter of the bearing (new) ... 24.882 to 24.892 mm (.9796 to .9800 in)
Maximum permissible clearance between bearing and bore in housing (worn) ... 0.15 mm (.006 in)
Torque for four nuts (put 5P3931 Anti-Seize Compound on threads) and bolts that hold turbocharger to exhaust manifold ... 55 ± 5 N·m (40 ± 4 lb ft)
NOTE: Put clean engine oil in the oil inlet of the turbocharger after assembly or before installation to provide start up lubrication and/or storage protection.
Compressor Wheel Clearance
a. Remove the compressor wheel from the cartridge group and place the wheel in the compressor housing. Center the wheel in the housing.
b. Measure the distance from the compressor housing mounting face to the compressor wheel seating face. Measure four places at approximately 90° increments. This is dimension "A" (Fig. 1).
c. Assemble the cartridge group complete except for the compressor wheel and shims. Hold the turbine wheel-shaft assembly toward the compressor end against the thrust bearing. Measure the distance from the bearing housing end face to the flinger sleeve. This is dimension "B" (Fig. 2).
d. Measure the distance from the bearing housing end face to the compressor housing mounting face of the bearing housing. This is dimension "C" (Fig. 2).
e. Shim thickness is C-B-A + 0.23 to 0.28 mm (C-B-A + .009 to .011 in). This is the thickness of the shims to be installed between the flinger sleeve and compressor wheel.
f. Shims to be of uniform thickness and free of burrs or other imperfections. Shim thickness should total 0.13 to 0.41 mm (.005 to .016 in) and consist of one or two shims selected from those specified in Step g. All measurements to be taken with dry (no lubrication) turbocharger.
g. Thickness of shims:
4W7362 Shim ... 0.076 mm (.003 in)
4W7357 Shim ... 0.127 mm (.005 in)
4W7358 Shim ... 0.152 mm (.006 in)
4W7359 Shim ... 0.178 mm (.007 in)
4W7360 Shim ... 0.203 mm (.008 in)
4W7361 Shim ... 0.229 mm (.009 in)
4W7363 Shim ... 0.254 mm (.010 in)
Turbocharger (S4D and C4D)
(1) End play for shaft (new) ... 0.114 ± 0.038 mm (.0045 ± .0015 in)
Maximum permissible end play (worn) ... 0.20 mm (.008 in)
(2) Thickness of thrust bearing (where thrust rings contact bearing) ... 5.36 ± 0.03 mm (.211 ± .001 in)
(3) Diameter of shaft (new) ... 15.997 to 16.005 mm (.6298 to .6301 in)
Bore in the bearing (new) ... 16.035 to 16.043 mm (.6313 to .6316 in)
Maximum permissible clearance between bearing and shaft (worn) ... 0.05 mm (.002 in)
(4) Maximum permissible gap of oil seal ring, measured in bore of housing ... 0.25 mm (.010 in)
(5) Install the compressor wheel (at room temperature) as follows:
a. Put compressor wheel on the shaft.
b. Put a small amount of clean engine oil on the threads.
c. Tighten the nut to 14 to 17 N·m (125 to 150 lb in).
| NOTICE |
|---|
Do not bend or add stress to the shaft when nut is loosened or tightened. |
d. Remove nut from shaft and apply 6V1541 Quick Cure Primer on the threads of the shaft and nut followed by application of 9S3263 Retaining Compound.
e. Tighten nut to 4 N·m (30 lb in).
f. Tighten nut more 90° rotation.
(6) Thickness of each thrust ring ... 2.553 ± 0.013 mm (.1005 ± .0005 in)
(7) Bore in housing (new) ... 24.994 to 25.006 mm (.9840 to .9845 in)
Outside diameter of the bearing (new) ... 24.882 to 24.892 mm (.9796 to .9800 in)
Maximum permissible clearance between bearing and bore in housing (worn) ... 0.15 mm (.006 in)
Tighten both band clamps (that hold the compressor and turbine housings to the cartridge group) with procedure that follows:
a. Tighten to ... 14 ± 1.1 N·m (125 ± 10 lb in)
b. Tap (hit) clamp lightly all around.
c. Tighten again to ... 14 ± 1.1 N·m (125 ± 10 lb in)
| NOTICE |
|---|
Do not overtighten the clamps. |
Torque for four nuts (put 5P3931 Anti-Seize Compound on threads) and bolts that hold turbocharger to exhaust manifold ... 55 ± 5 N·m (40 ± 4 lb ft)
NOTE: Put clean engine oil in the oil inlet of the turbocharger after assembly or before installation to provide start up lubrication and/or storage protection.
Turbocharger (S3B and C3B)
(1) End play for shaft (new) ... 0.102 ± 0.025 mm (.004 ± .001 in)
Maximum permissible end play (worn) ... 0.20 mm (.008 in)
(2) Thickness of thrust bearing (where thrust rings contact bearing) ... 5.36 ± 0.03 mm (.211 ± .001 in)
(3) Diameter of shaft (new) ... 12.697 to 12.705 mm (.4999 to .5002 in)
Bore in the bearing (new) ... 12.741 to 12.748 mm (.5016 to .5019 in)
Maximum permissible clearance between bearing and shaft (worn) ... 0.05 mm (.002 in)
(4) Maximum permissible gap of oil seal ring, measured in bore of housing ... 0.25 mm (.010 in)
(5) Install the compressor wheel (at room temperature) as follows:
a. Put compressor wheel on the shaft.
b. Put a small amount of clean engine oil on the threads.
c. Tighten the nut to 14 to 17 N·m (125 to 150 lb in).
d. Remove nut from shaft and apply 6V1541 Quick Cure Primer on the threads of the shaft and nut followed by application of 9S3263 Retaining Compound.
e. Tighten nut to a torque of ... 24 ± 2 N·m (216 ± 12 lb in)
| NOTICE |
|---|
Do not bend or add stress to the shaft when the nut is loosened or tightened. |
(6) Thickness of each thrust ring ... 2.553 ± 0.013 mm (.1005 ± .0005 in)
(7) Bore in housing (new) ... 20.744 to 20.757 mm (.8167 to .8172 in)
Outside diameter of the bearing (new) ... 20.630 to 20.643 mm (.8122 to .8127 in)
Maximum permissible clearance between bearing and bore in housing (worn) ... 0.15 mm (.006 in)
Torque for four nuts (put 5P3931 Anti-Seize Compound on threads) and bolts that hold turbocharger to exhaust manifold ... 55 ± 5 N·m (40 ± 4 lb ft)
Install the band clamps to hold the cartridge to the compressor housing as follows:
a. Tighten clamps to ... 14 ± 1.1 N·m (125 ± 10 lb in)
b. Tap (hit) clamp lightly all around.
c. Tighten again to ... 14 ± 1.1 N·m (125 ± 10 lb in)
NOTE: Put clean engine oil in the oil inlet of the turbocharger after assembly or before installation to provide start up lubrication and/or storage protection.
Turbocharger TV71, TV72 And TV78
(1) Nut for impeller (See Turbocharger Impeller Installation).
| NOTICE |
|---|
Do not bend or add stress to the shaft when the nut is loosened or tightened. |
(2) Torque for the bolts that hold the backplate ... 11 ± 1 N·m (98 ± 10 lb in)
(3) Torque for the clamp bolts ... 14.0 ± 1.5 N·m (120 ± 13 lb in)
Lightly hit all around clamp with a soft faced hammer and again tighten to ... 14.0 ± 1.5 N·m (120 ± 13 lb in)
(4) Bore in the bearings ... 15.921 to 15.931 mm (.6268 to .6272 in)
Diameter for the surfaces (journals) on the shaft for the bearings ... 15.875 to 15.885 mm (.6250 to .6254 in)
(5) Bore in the housing ... 24.961 to 24.973 mm (.9827 to .9832 in)
Outside diameter of the bearing ... 24.846 to 24.859 mm (.9782 to .9787 in)
(6) Clearance between the ends of the oil seal ring (when installed in its bore) ... 0.20 to 0.38 mm (.008 to .015 in)
(7) Endplay for the shaft ... 0.08 to 0.25 mm (.003 to .010 in)
(8) Torque for bolts and nuts that hold the turbocharger to the exhaust manifold (put 5P3931 Anti-Seize Compound on the threads) ... 55 ± 5 N·m (40 ± 4 lb ft)
Turbocharger TV75
(1) Torque for the bolts that hold the backplate ... 11 ± N·m (98 ± 10 lb in)
(2) Bore in the bearings ... 15.921 to 15.931 mm (.6268 to .6272 in)
Diameter for the surfaces (journals) on the shaft for the bearings ... 15.875 to 15.885 mm (.6250 to .6254 in)
(3) Bore in the housing ... 24.961 to 24.973 mm (.9827 to .9832 in)
Outside diameter of the bearing ... 24.846 to 24.859 mm (.9782 to .9787 in)
(4) Clearance between the ends of the oil seal ring (when installed in its bore) ... 0.20 to 0.38 mm (.008 to .015 in)
(5) Torque for bearing bolts ... 3.35 to 3.85 N·m (30 to 34 lb in)
(6) Nut for impeller (See Turbocharger Impeller Installation).
| NOTICE |
|---|
Do not bend or add stress to the shaft when the nut is loosened or tightened. |
(7) Endplay for the shaft ... 0.08 to 0.13 mm (.003 to .005 in)
Torque for the clamp bolts ... 14.0 ± 1.5 N·m (120 ± 13 lb in)
Lightly hit all around clamp with a soft faced hammer and again tighten to ... 14.0 ± 1.5 N·m (120 ± 13 lb in)
Torque for bolts and nuts that hold the turbocharger to the exhaust manifold (put 5P3931 Anti-Seize Compound on the threads) ... 55 ± 5 N·m (40 ± 4 lb ft)