Page 426
REPAIR INSTRUCTIONS, PART 2
Turbocharger Installation (Includes
Pre-Lubing Procedures)
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.
A thorough inspection is required as even small
particles can cause severe rotor damage if
inducted during high-speed operation.
2. Use 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.
The turbocharger-to-manifold gasket is unique for
the VTG turbocharger. When installing the
turbocharger, be sure to use the correct gasket;
the gasket used with a standard turbocharger will
not work for this application.
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
(Figure 516).
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 517) in two
stages:
앫 First stage — 50 lb-ft (68 N폷m)
앫 Second stage — 100 lb-ft (136 N폷m)
517
Figure 517 — Turbocharger Tightening Sequence
The mounting nut at the upper front location is
difficult to access and will require the use of an
offset wrench or crow’s foot to tighten.
5. Support the exhaust pipe to prevent it from
dropping onto the EGR hot tube bellows.
Then, install the exhaust bracket to the
flywheel housing and install the exhaust
clamp at the turbocharger.
DO NOT let the exhaust pipe drop onto the
bellows of the EGR hot tube as the exhaust pipe
clamp is being installed at the turbocharger. The
bellows could be damaged requiring replacement
of the hot tube.
6. Fill the oil inlet port to overflowing with clean
engine oil. Next, using your fingers at the
compressor wheel, carefully spin and wiggle
the turbocharger shaft to distribute the oil
over all bearing surfaces. Then, again fill the
oil inlet port to overflowing.
5-111.bk Page 426 Monday, July 10, 2006 2:26 PM
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