Usage:
1. Disconnect hose assemblies (4) and (5) from elbow (6).
2. Loosen the clamps that hold hose (1) in place, and move hose (1) away from elbow (6).
3. Remove the bolt, lock and elbow (6) from the turbocharger.
4. Loosen the clamps that hold elbow (7) in place, and move the elbow away from the turbocharger.
5. Remove tube assemblies (8) and (9).
6. Remove the clamp that holds pipe assembly (2) in position, and move the pipe assembly away from the turbocharger.
7. Fasten a hoist to turbocharger (3). Remove the nuts that hold the turbocharger to the exhaust manifold, and remove the turbocharger. The weight of the turbocharger is 23 kg (51 lb.).
NOTE: The following steps are for installation of the turbocharger.
8. Install the gasket between the turbocharger (3) and the exhaust manifold. Put 5P3931 Anti-Seize Compound on the threads of the bolts, and install the bolts and nuts that hold the turbocharger to the exhaust manifold. Tighten the bolts to a torque of 55 ± 5 N·m (41 ± 4 lb.ft.).
9. Make sure the gaskets are in position on tube assemblies (8) and (9), and install the tube assemblies.
10. Put pipe assembly (2) in position on the turbocharger, and install the clamp that holds it.
11. Put elbow (7) in position on the turbocharger, and install the clamps that hold it in place.
12. Put elbow (6) in position in the turbocharger and hose (1). Tighten the clamps that hold the hose to the elbow.
13. Install the lock and bolt to hold elbow (6) in position in the turbocharger.
14. Connect hose assemblies (4) and (5) to elbow (6).
Disassemble Turbocharger (S4A)
START BY:
a. remove turbocharger (S4A)
1. Install the turbocharger on tool (A) as shown.
2. Put alignment marks on three housings of the turbocharger for correct alignment during assembly. Loosen clamp (2), and remove the clamp and housing (1) from housing assembly (3).
3. Loosen clamp (4), and remove housing assembly (3) from housing (5).
4. Put the cartridge group in position in tool (B) as shown.
| NOTICE |
|---|
When the nut is loosened, do not put a side force on the shaft. This can result in a bent shaft. |
5. Use a 5S9566 Sliding T-Wrench and a universal socket (6) to remove the nut that holds the compressor wheel to the wheel assembly.
6. Remove compressor wheel (7) and the shims from wheel assembly (8).
7. Remove housing assembly (3) from wheel assembly (8).
8. Remove ring (9) and backplate (10) from wheel assembly (8).
9. Use tool (C), and remove snap ring (11) from housing assembly (3).
10. Remove insert (12) and sleeve (13) from housing assembly (3).
11. Remove ring (14) from sleeve (13).
12. Remove two screws (15) and deflector (16) from housing assembly (3).
13. Remove ring (18) and bearing assembly (17) from the housing assembly.
14. Remove sleeve (19) and ring (20) from the housing assembly.
15. Remove O-ring seal (23) from the housing assembly.
16. Use tool (D), and remove snap ring (22) from the housing assembly.
17. Remove bearing (21). Remove the snap ring behind the bearing with tool (D).
18. Use tool (D), and remove snap ring (25) from the housing assembly.
19. Remove bearing (24). Remove the snap ring behind the bearing with tool (D).
20. Check all the parts of the turbocharger for damage. If the parts are damaged, use new parts for replacement. See Special Instruction, Form No. SMHS6854 for Turbocharger Reconditioning. Also see Guidelines For Reusable Parts, Form No. SEBF8018.
Assemble Turbocharger (S4A)
1. Make sure that all of the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material.
NOTE: Do not put oil on any parts of the turbocharger until after the compressor wheel has been installed. After the turbocharger has been assembled, pour clean engine oil into the oil inlet of the turbocharger.
| NOTICE |
|---|
Make sure that the snap rings that hold bearings (2) and (5) in position in housing assembly (3) are installed with the round edge of the outside diameter toward the bearing. |
2. Install the snap ring behind bearing (2) with tool (A).
3. Install bearing (2) in housing assembly (3).
4. Use tool (A), and install snap ring (1) in the housing assembly.
5. Install the snap ring behind bearing (5) with tool (A).
6. Install bearing (5) in the housing assembly.
7. Use tool (A), and install snap ring (4) in the housing assembly.
8. Put wheel assembly (8) in position on tool (B) as shown.
9. Put backplate (7) in position on the wheel assembly.
NOTE: Put 6V2055 High Vacuum Grease in the groove for seal ring (6) at assembly to one half or more of the depth of the groove all the way around.
10. Install ring (6) in the groove in wheel assembly (8).
11. Put housing assembly (3) in position on wheel assembly (8).
12. Install ring (9) and sleeve (10) on the wheel assembly.
13. Make sure the screen is in place in bearing assembly (11).
14. Install bearing assembly (11) over the sleeve. Make sure the screen in the bearing assembly is facing down when it is installed.
15. Put ring (12) in position on bearing assembly (11).
16. Put deflector (14) in position in the housing assembly, and install two screws (13).
NOTE: Put 6V2055 High Vacuum Grease in the groove of sleeve (15) to one half or more of the depth of the grooves all the way around.
17. Install ring (16) in the groove in sleeve (15).
18. Put sleeve (15) in position in insert (17). Install the insert and sleeve (15) as an assembly.
19. Use tool (C), and install snap ring (18) to hold insert (17) in place.
20. Put wheel (21) in position in compressor housing (20). Center the wheel in the compressor housing.
21. Use a straight edge and a depth micrometer (19), and measure the distance between the wheel seating face and the compressor housing mounting face (dimension X) in four places. Find the average of the measurements.
22. Use a depth micrometer (19) to measure the distance between the surface of housing assembly (3) and the surface of sleeve (15) (dimension Y).
23. Use a depth micrometer (19), and measure the distance between the surface of housing assembly (3) and the compressor housing mounting face (dimension Z).
24. Calculate the necessary shim thickness as follows:
NOTE: The shims must be of uniform thickness and free of burrs and other imperfections. The total shim thickness should be 0.13 mm to 0.41 mm (.005 to .016 in.) and consist of one or two shims.
25. Install wheel (21) at room temperature as follows:
a. Put the correct amount of shims and wheel (21) in position on the wheel assembly.
b. Put a small amount of clean engine oil on the threads of the wheel assembly.
| NOTICE |
|---|
Do not put a side force on the shaft when the nut that holds the compressor wheel in position is tightened. |
c. Install the nut that holds wheel (21) in place. Tighten the nut to a torque of 14 to 17 N·m (125 to 150 lb.in.).
d. Remove the nut, and put 6V1541 Quick Cure Primer on the threads of the wheel assembly.
e. Put 9S3265 Retaining Compound on the threads of the wheel assembly, and install the nut. Tighten the nut to a torque of 4 N·m (35 lb.in.).
f. Tighten the nut an additional 90°.
26. Install housing (23) on tool (D) as shown.
27. Put housing assembly (3) in its original position in housing (23), and install clamp (22).
28. Tighten clamp (22) to a torque of 14 ± 3 N·m (10 ± 2 lb.ft.). Tap the clamp lightly all the way around, and retighten it to a torque of 14 ± 3 N·m (10 ± 2 lb.ft.).
29. Put housing (24) in its original position on housing assembly (3), and install clamp (25).
30. Tighten clamp (25) to a torque of 14 ± 3 N·m (10 ± 2 lb.ft.). Tap the clamp lightly all the way around, and tighten the clamp again to the same torque valve.
END BY:
a. install turbocharger (S4A)