Usage:
Introduction
When a turbocharger repair is necessary for one of the above engines, a 9Y1669 Turbo Kit can be installed. Installation of this kit in the C4A Turbocharger will update the turbocharger and provide better thrust bearing retention.
Reference: Service Manual, Parts Book and Guideline For Reusable Parts-Turbocharger, Form SEBF8018.
Installation of 9Y1669 Turbo Kit
1. Remove the turbocharger from the engine and disassemble it according to the procedure in the specific Service Manual.
2. Parts in the existing turbocharger that will be replaced with parts from the 9Y1669 Turbo Kit are as follows: (2) Machine Screws (two), (3) Insert, (4) Piston Ring, (5) Piston Ring, (6) Bearings (two) and (7) Retaining Rings (four) for bearings (6).
NOTE: At time of disassembly, save the original shim pack that was used for the end clearance adjustment of compressor wheel (1). Some of these shims may be needed again when the compressor wheel is installed later in this instruction.
3. Check all turbocharger parts for damage. If any parts that are to be used again have damage or wear, use new parts for replacement. Refer to Form SEBF8018 " Guideline For Reusable Parts, Turbochargers".
4. Make sure that all oil passages in the turbocharger center housing are clean and free of dirt and foreign material.
NOTE: Do not put oil on any turbocharger parts until after the compressor wheel is installed. After the turbocharger has been assembled, pour clean engine oil into the oil inlet of the turbocharger.
5. Assemble the turbocharger cartridge using the new parts from the 9Y1669 Turbo Kit and any other new parts that are needed. Be sure the retaining rings are installed correctly (smooth side toward the bearing) as indicated in the Service Manual.
6. When installing the new 9B1722 Machine Screws as replacements for original machine screws (2), tighten the new machine screws to a torque of 2.25 ± 25 N·m (20 ± 2 lb in).
NOTE: Before installing the compressor wheel, check compressor wheel to compressor housing clearance.
8. Put compressor wheel (1) in compressor housing (8) as shown. Center the wheel in the housing.
NOTE: Measurements (A), (B) and (C) are to be taken with all parts dry (no lubrication).
9. Measure the distance from compressor housing (8) mounting face-to-compressor wheel (1) seating face, dimension (A). Measure four places at approximately 90° increments.
10. With the cartridge group completely assembled 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, dimension (B).
11. Measure the distance from the bearing housing end face to the compressor housing mounting face, dimension (C).
NOTE: The formula that follows: (C) - (B) - (A) + 0.39 to 0.43 mm [(C) - (B) - (A) + .015" to .017"] normally results in a negative (-) number between 0 and 0.28 mm (0 and .011"). If, however, the dimension obtained is positive (+) and less than 0.13 mm (.005"), use no shims. If the dimension obtained is more than 0.13 mm (.005"), check the parts and assembly dimensions. Replace parts as necessary.
12. Shim thickness needed is: (C) - (B) - (A) + 0.39 to 0.43 mm [(C) - (B) - (A) + .015" to .017"]. This is the thickness of shims that will need to be installed between the flinger sleeve and the compressor wheel.
NOTE: The compressor wheel clearance may be 0.13 mm (.005") greater than the original factory assembly specifications. When shims are required, use shims from the original shim pack and the necessary shims from the new turbo kit, to get the correct shim pack thickness needed. It will be necessary to measure each individual shim used in the original shim pack to determine shim thickness.
13. Shims are to be of uniform thickness and free of burrs or other imperfections. Shim thickness should total 0 to 0.28 mm (0 to .011") and consist of shims from the original shim pack plus shims from the new turbo kit. Use the shim thickness chart that follows for the thickness of the shims that can possibly be in the original shim pack removed from the turbocharger at disassembly. All measurements are to be taken with turbocharger parts dry (no lubrication).
14. After the correct amount of shims have been put in position between the surface of the sleeve and the compressor wheel, install the compressor wheel on the shaft (compressor wheel to be at room temperature) as follows:
A. Put compressor wheel (1) in position on the shaft.
B. Put a small amount of clean engine oil on the shaft threads.
C. Put the nut on the shaft threads. Use a universal socket (9) with a torque wrench to tighten the nut to a torque of 14 to 17 N·m (125 to 150 lb in).
| NOTICE |
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Do not bend or add stress to the shaft when the nut is being tightened or loosened. Use universal socket (9) as shown. |
D. Remove the nut. Put 6V1541 Quick Cure Primer on the threads of nut and shaft, followed by an application of 9S3265 Retaining Compound.
| NOTICE |
|---|
Do not bend or add stress to the shaft when the nut is being tightened or loosened. Use universal socket (9) as shown. |
E. Again put the nut on the shaft threads. Use universal socket (9) with a torque wrench to tighten the nut to a torque of 4 N·m (30 lb in).
F. Now tighten the nut more as follows:
- * For 99.0 mm (3.9")Ø compressor wheels (most 3400 Engines), tighten the nut an additional 90°.* For 86.4 mm (3.4")Ø compressor wheels (most 3300 Engines), tighten the nut an additional 60°.
15. Complete the assembly of the turbocharger. See the Service Manual for procedure and specifications.