Page 342
REPAIR INSTRUCTIONS, PART 1
Turbocharger Installation
[214 SC]
Refer to Figure 403.
A thorough inspection is required as even small
particles can cause severe rotor damage if
inducted during high-speed operation.
Use only new and approved gaskets at the
various air, oil and exhaust connections to the
turbocharger. Avoid the use of sealing or jointing
compounds at all flanged connections.
After completing the reassembly of the engine,
the turbocharger must be prelubricated with clean
engine oil before starting the engine. Refer to the
procedure under “Turbocharger” in the ENGINE
PREPARATION AND OPERATIONAL CHECK
section.
1. Inspect the intake and exhaust systems
leading to and from the turbocharger to
ensure absence of foreign material,
including burrs and loose lining fragments.
Place protective caps over the compressor
and turbine outlets to keep debris and dirt
out of the turbocharger as engine
reassembly progresses.
2. Install a new turbocharger gasket over the
four mounting studs.
The turbocharger is heavy, weighing
approximately 76 lbs. DO NOT attempt to remove
or install the turbocharger without the help of an
assistant or the use of a suitable lifting device.
3. Place the turbocharger in position over the
mounting studs on the exhaust manifold.
4. Apply a coating of clean engine oil to the
flanges and threads of the four nuts. Install
the nuts and using torque wrench J 24406,
or equivalent, tighten the nuts in a
cross-pattern sequence (Figure 402) in two
stages:
앫 First stage — 50 lb-ft (68 N폷m)
앫 Second stage — 100 lb-ft (136 N폷m)
402
Figure 402 — Turbocharger Tightening Sequence
5. Inspect the turbocharger oil supply line to
make sure it is flushed clean and free of all
debris. Then, install the supply line.
6. Place the oil drain tube in position between
the port on the engine block and the
turbocharger. Apply anti-seize compound to
the threads of the capscrews and install the
capscrews. Tighten the capscrews to the
specified torque, 15 lb-ft (20 N폷m), using
torque wrench J 24406, or equivalent.
If the VTG actuator has been removed, refer to
“VTG TURBOCHARGER SERVICE
PROCEDURES (ASET™ AC ENGINE)” for
installation and adjustment procedures.
5-111.bk Page 342 Monday, July 10, 2006 2:26 PM
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