Usage:
START BY:
a. install body support (FT1437) or body retaining pins
1. Lift the hoods, and fasten them in position with the hood locks.
2. Turn the battery disconnect switch to the OFF position. This will insure the engine cannot be started.
3. Remove flexible pipe (1) and elbow (2).
4. Remove turbocharger oil supply tube (4).
5. Remove the bolts that hold the turbocharger oil drain line to the turbocharger.
6. Remove the bolts that hold turbocharger (3) to manifold (5).
7. Fasten tooling (A) and a hoist to turbocharger (3). The weight of the turbocharger is 27 kg (60 lb.).
8. Carefully move turbocharger (3) away from adapter (6) and pipe (7).
9. Put protective covers in all air and oil openings.
10. Put turbocharger (3) in a plastic bag. Seal the bag and store the turbocharger in a safe, clean place.
Install Turbocharger (4MF)
1. Remove the protective covers.
2. Install a new gasket on the turbocharger oil return tube.
3. Install a new turbocharger mounting gasket (4).
4. Install a new carbon ring on coupling (3).
5. Install new seals on pipe (2), and put clean engine oil on them.
6. Install tool (A) and carefully move turbocharger (1) into position on the manifold.
7. Be sure the turbocharger oil return tube gasket is in place, and install the bolts to hold the oil return tube to the turbocharger.
8. Put 5P3931 Anti-Seize Compound on the threads of bolts (8) that hold the turbocharger to the exhaust manifold. Tighten the bolts to a torque of 55 ± 5 N·m (41 ± 4 lb.ft.).
9. Install a new gasket for turbocharger oil supply tube (9), and install it.
10. Put new O-ring seals on elbow (10), and put clean engine oil on them.
11. Install elbow (10) into turbocharger (1), and install the bolts to hold the elbow.
12. Install pipe (11) with new gaskets.
13. Turn the battery disconnect switch to the ON position.
14. Lower the hoods.
END BY:
a. remove body support (FT1437) or body retaining pins
Disassemble Turbocharger (4MF)
START BY:
a. remove turbocharger
NOTE: Put alignment marks on the turbocharger sections for correct assembly.
1. Put turbocharger (1) in position on tool (A). Loosen clamp (3), and remove compressor housing (2).
2. Loosen clamp (4). Remove cartridge assembly (5) from turbine housing (6).
3. Put the cartridge assembly in position on tool (B). Use correct size socket holder.
| NOTICE |
|---|
When nut is removed, do not put a side force on the shaft. The shaft can bend. |
4. Remove the nut with tool (C) and a universal socket. Remove compressor wheel (7).
NOTE: If the compressor wheel cannot be removed easily, use a press to remove it.
5. Remove housing (8) from the shaft.
6. Remove heat shroud (9) from the shaft.
7. Remove ring (11) from the shaft of wheel assembly (10).
8. Remove snap ring (12) from the housing. Use tool (E).
9. Remove insert (13) from the housing.
10. Push sleeve (14) from the insert with fingers. Remove the seal ring from the sleeve.
11. Remove O-ring seal (15) from the insert.
12. Remove deflector (16). Remove two rings, sleeve and bearing (not shown) from the housing.
13. Remove snap ring (17), bearing (18) and the inner snap ring. Use tool (D) to remove the snap rings.
14. Turn the housing as shown. Remove snap ring (20), bearing (19) and the inner snap ring. Use tool (D) to remove the snap ring.
15. For information in analyzing turbocharger failures, see Analyzing Turbocharger Failures, Form No. FEG45138.
Assemble Turbocharger (4MF)
1. Make sure all oil passages are open and all parts are clean and free of dirt and foreign material. Put clean engine oil on all parts before assembly.
NOTE: Use tool (A) to install snap rings with round outside edge toward the bearing.
2. Install snap ring (1), bearing (2) and snap ring (3) in the exhaust end of housing (7).
3. Turn the housing over as shown. Install snap ring (4), bearing (5) and snap ring (6).
| NOTICE |
|---|
Put the holes in bearing and deflector in alignment with the dowels in housing. |
4. Install ring (12), bearing (11), sleeve (10), ring (9) and deflector (8) in the housing.
5. Install O-ring seal (13) on insert (14). Install ring (15) on sleeve (16).
6. Install sleeve (16) into insert (14).
7. Install insert (14) in the housing.
8. Install snap ring (17) with tool (B).
9. Put wheel assembly (19) in position in tool (C). Put 6V2055 High Vacuum Grease in the ring groove. Make sure the grease fills the groove approximately one half or more of the groove to help make a carbon dam under the seal ring. Install ring (18) on the shaft of the wheel assembly.
10. Install shroud (20) on the wheel assembly.
11. Put the cartridge housing in position on the wheel assembly. Make sure the ring on the wheel assembly is fitted correctly in the housing.
| NOTICE |
|---|
Use a universal socket with a torque wrench. Do not put a side force on the shaft when the nut is tightened. The shaft may bend. |
12. Put clean engine oil on the threads of the shaft and the nut face of wheel (21). Install the nut on the shaft, and use the procedure which follows to tighten it.
a. Use a universal socket to tighten the nut to a torque of 60 ± 3 N·m (44 ± 2 lb.ft.).
b. Remove the nut from the shaft, and put 6V1541 Quick Cure Primer on the threads of the nut and the threads of the shaft.
c. Put 9S3265 Retaining Compound on the threads of the nut and the shaft.
d. Install the nut, and tighten it again to a torque of 60 ± 3 N·m (44 ± 2 lb.ft.).
13. Put cartridge housing in a vise as shown. Check the shaft end play with tool (D). The end play must be 0.114 ± 0.038 mm (.0045 ± .0015 in.). If the shaft end play is not correct, check Specifications for too much wear.
14. Install turbine housing (22) on tool (E). Put the cartridge housing in position in the turbine housing. Make sure the marks are in alignment on the housing. Install the "V" clamp, and tighten the bolt to a torque of 13.6 ± 1.1 N·m (120 ± 10 lb.in.).
15. Put compressor housing (23) in position on the cartridge housing. Make sure the marks on the housings are in alignment. Install the "V" clamp that holds the compressor housing to the cartridge housing. Tighten the bolt to a torque of 13.6 ± 1.1 N·m (120 ± 10 lb.in.).
END BY:
a. install turbocharger