Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool. |
At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury. |
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Install caps and plugs on all openings to prevent dirt or debris from entering the system. Cleanliness is an important factor. Before the removal procedure, the exterior of the component must be cleaned thoroughly to prevent dirt from entering the internal mechanism. |
NOTICE |
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Do not reuse the exhaust bellows or the clamps for the bellows. The used parts will loosen and the joint will separate. Always install new bellows and clamps. |
- Release the system pressure. Refer to Operation and Maintenance Manual, "System Pressure Release".
- Drain the coolant into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change".
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Illustration 1 g03141396 - Remove panels (1).
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Illustration 2 g03381845 - Disconnect hose (2), V-band clamps (3), and bellows (4).
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Illustration 3 g03381841 - Disconnect hose assemblies (5), hose assemblies (6), clamps (7), and bellows (8).
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Illustration 4 g03381838 - Disconnect V-band clamps (9) and bellows (10).
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Illustration 5 g03381843 Show/hide tableIllustration 6 g03381840 Show/hide tableNOTICE Do not step on the turbochargers. Doing so can damage the turbocharger and shorten the turbocharger life.
Show/hide tableNOTICE If the turbine housing or the compressor housing must be rotated to remove the turbocharger, loosen the V-band clamps only enough to allow for rotation (typically 7-10 turns). If the V-band clamps are loosened excessively, the housing may contact the turbine wheel or the compressor wheel and cause damage. Contact with the housing may cause rapid wear and shorten turbocharger life.
- Attach a suitable lifting device to turbocharger (11). The weight of turbocharger (11) is approximately
79 kg (175 lb) . - Remove bolts (12). Mark the orientation of V-band clamp (13). If necessary, loosen V-band clamp (13). Remove turbocharger (11).
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Illustration 7 g03381842 - Remove screen assembly (14) and O-ring seal (15).
Required Tools | |||
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Tool | Part Number | Part Description | Qty |
A | - | Loctite C5A Copper Anti-Seize | - |
NOTICE |
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Do not reuse the exhaust bellows or the clamps for the bellows. The used parts will loosen and the joint will separate. Always install new bellows and clamps. |
- Install O-ring seal (15) and screen assembly (14).
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Illustration 9 g03381839 Show/hide tableIllustration 10 g03381843 Show/hide tableNOTICE Follow the procedure for bellows installation and tightening procedures. Tighten the V-band clamps on the turbine housing prior to the bellows V-band clamp to prevent any dragging or binding of the turbocharger rotating components. Contact may cause rapid wear and shorten turbocharger life.
- Ensure turbocharger (11) is aligned with dowel (X) and oil drain fitting (Y). Use a suitable lifting device to install turbocharger (11). The weight of turbocharger (11) is approximately
136 kg (300 lb) . - Install bolts (12).
- Do not tighten V-band clamp (13) at this time.
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Illustration 11 g03381838 - Connect bellows (10) and V-band clamps (9).
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Illustration 12 g03381841 - Refill the oil inlet with clean oil. Connect bellows (8), clamps (7), hose assemblies (6), and hose assemblies (5).
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Illustration 13 g03381845 - Connect bellows (4), V-band clamps (3), and hose (2).
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Illustration 14 g03381840 - Apply Tooling (A) onto the stud of V-band clamp (13). Tighten V-band clamp (13) to a torque of
20 N·m (177 lb in) . Loosen V-band clamp (13) by two to three turns. Tap lightly with a suitable hammer around the diameter of V-band clamp (13). Tighten V-band clamp (13) to a final torque of30 ± 2 N·m (266 ± 18 lb in) . - Tighten V-band clamps (9) and V-band clamps (7) to a torque of
6.5 ± 2 N·m (58 ± 18 lb in) . Tighten V-band clamps (3) to a torque of8.5 ± 2 N·m (75 ± 18 lb in) . - Ensure that the compressor wheel spins freely without binding or dragging. Contact with the housing may cause rapid wear and shorten turbocharger life.
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Illustration 15 g03141396 - Install panels (1).
- Refer to Specifications, "Turbocharger".
- Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct draining and filling procedure.
Illustration 8 | g03381842 |