Case Series C - Turbocharger System Removal

22-4
TURBO CHARGER SYSTEM
Four Cylinder 336BDT Engine
(Refer to Figure 4)
Removal
Remove the muffler and hood from the vehicle. Steam clean the engine thoroughly before
removing any components for service.
1. Disconnect the air cleaner from the
turbo-charger.
2. Disconnect the turbo and intake elbow
hose clamps(l)and remove withhose(2).
3. Disconnect the turbo oil supplyline(3)
and remove. Disconnect hose clamps (4)
and remove the oil drain tube hose (5) .
Remove the oil drain tube (6) with gasket
(7). Discard gasket.
4. Remove the intake elbow (8) with gasket
(9). Discard gasket.
5. Remove the turbo-charger (10), gasket
(11) and coupler (12). Discard gasket (11).
6. Remove the bolts from the manifold brace
(1 7). Remove the exhaust elbow (13) and
spacers (18) .
7. Remove the turbo adapter base (14) with
gasket (15). Discard gasket.
8. Remove the oil drain tube elbow (16).
Inspection
Clean the intake and exhaust elbows,
coupler and turbo adapter thoroughly and
check for cracks or other damage. Replace
if necessary.
Flush and clean the oil supply line, oil
drain tube and elbow. Check foranydamage
and replace if necessary.
Replace the hose clamps to assure air
tight and leak proof connections.
Check the hoses for cracks and deter-
ioration. Replace if necessary.
Installation
1. Install the intake elbow (8) with a new
gasket (9) to the intake manifold. Retain
with bolts and nuts and torque 35
to
42
ft. pounds.
2. Install the exhaust elbow (13) and spacers
(18) to the water manifold. Retain with
bolts finger tight.
3. Install the turbo adapter base (14) with a
new gasket (15) to the exhaust manifold.
Retain with bolts and nuts and torque 35
to 42 foot pounds.
4.lnstall a new gasket (11) to the turbo-
adapter base and install the turbo-charger
(10) to the adapter base with the coupler
(12). Retain the turbo-charger with nuts
and bolts finger tight.
IMPORTANT -
Align
the turbo-charger (10), coupler (12) and
and the exhaust elbow (13) so that the
coupler is free to rotate 360°. Torque the
exhaust elbow bolts and the turbo-charger
bolts and nuts 35 to 42 ft. pounds.
NOTE
recheck that the coupler rotates 360°.
5. Install the brace (17) to the exhaust elbow
(13) and retain with bolts. Torque 35 to
42 ft. pounds.
6. Install the turbo oil supply line (3).
7. Install the turbo oil drain tube (6) with a
new gasket (7). Torque the retaining bolts
35
to
42 ft. pounds.
8. Install the drain tube elbow (16), with the
hose end in a vertical angle position. In-
stall new hose clamps (4) and hose (5),
connecting the elbow (16) to the drain tube
(6). Position the clamps and tighten
securely.
9. Install the new hose clamps (1) and hose
(2), connecting the intake elbow (8) and
turbo-charger (10). Position the clamps
and tighten securely.