Turbocharger Rebuild

DISASSEMBLY OF THE TURBOCHARGER





Scribe the housings so they can be reassembled in the same position as before disassembly.





Clamp the turbocharger in a bench vise.





Remove the compressor housing V-band clamps.





Remove the compressor housing and inspect for impeller contact.

Remove the square cut 0-ring.





Remove the impeller nut.

CAUTION: Turn the nut to the right to loosen. The nut and shaft have left hand threads.





Remove the impeller and inspect the blades for damage.

CAUTION: The wheel and shaft assembly is balanced as a unit. If the impeller is damaged the complete assembly must be replaced.





Remove the diffuser capscrews end lockplate.





Remove the diffuser and discard the o-ring.





Remove the oil slinger and discard the piston ring. Inspect for cracks and excessive wear.





Remove the oil baffle.





Remove the thrust bearing and retainer screws.

CAUTION: Do not reuse the thrust bearing.





Remove the thrust collar. Inspect the collar for excessive wear.





Remove the turbine housing lockplates and clamp plates.





Remove the bearing housing.





Remove the turbine shaft and heat shield.

Inspect the turbine blades and the shaft for excessive wear.





Remove and discard the piston ring type seal.

CAUTION: The wheel and shaft assembly is balanced as a unit. If the turbine blades or shaft are damaged, the complete assembly must be replaced.





Remove and discard the outer retainer rings.





Remove and discard the turbocharger shaft bearings.





Remove and discard the inner snap rings.

CLEANING OF THE TURBOCHARGER





Use a stiff bristle nylon brush and solvent to clean all parts.

CAUTION: Do not use a wire brush on the compressor wheel. Do not bead blast the parts.





Remove the carbon build up from the housing with a scraper and 240 grit emery cloth.





Polish the bearing surfaces with crocus cloth and kerosene or diesel fuel.





After rinsing in clean solvent, use compressed air to dry the parts.

INSPECTION OF THE TURBOCHARGER





In addition to the inspection specified during disassembly, inspect all parts after cleaning.

Measure the shaft bearing diameter.

Diameter: 10.97mm MIN [0.432 inch]

ASSEMBLY OF THE TURBOCHARGER





The balance marks must be aligned to make sure the wheel and shaft assembly is balanced





Install the piston ring and lubricate the groove with engine oil.





Install the heat shield.





Clamp a socket in a soft jawed vice and position the shaft in the socket.





Install the inner retainer rings.

CAUTION: The beveled face must be towards the bearing.





Lubricate the turbocharger bearings with engine oil and install the bearings in the housing.





Install the outer retainer ring.

CAUTION: The beveled face must be towards the bearings.





Assemble the turbine shaft and heat shield to the bearing housing.

CAUTION: Rotating the housing as you press downward will assist in properly seating the piston ring.





Install the thrust collar.

CAUTION: Align the balance mark with the balance mark on the shaft. Mark the top surface with a marker pen so alignment can be verified after installing the thrust bearing.





Lubricate the thrust bearing with engine oil and install it on the housing.

Torque Value: 4.5 N-m [40 in-lbs]





Install the oil baffle.

CAUTION: Check the balance mark alignment.





Install the piston ring type seal on the oil slinger.





Mark the top surface of the oil slinger in line with the balance mark.





Lubricate the oil slinger with engine oil and install it into the diffuser.





Install the 0-ring into the diffuser.





Install the diffuser.

CAUTION: Align the balance marks on the shaft and the oil slinger.





Align the balance mark and install the impeller.

CAUTION: Be careful not to move the bearing housing.





CAUTION: Impeller nut and shaft have left hand threads.

Do not allow the impeller to turn when installing the nut.

Torque Value: 14 N-m [129 in-lbs]





Install the bearing housing assembly into the turbine housing.





Align the scribe marks.





Apply anti-seize compound to the capscrew threads.





Install the clamp plates, lockplates and capscrews.

Torque Value: 11.3 N-m [100 in-lbs]





Install the lockplates and capscrews into the diffuser.

After tightening the capscrews, bend the lockplate tabs to lock the capscrews.

CAUTION: Be sure the scribe marks are aligned.

Torque Value: 5.7 N-m [50 in-lbs]





Measure the end play.

End Play

MIN 0.001 in.
MAX 0.003 in.

* For turbochargers with a serial number after and including 840638.





Measure radial clearance of the shaft.

Radial Clearance

MIN 0.012 in.
MAX 0.018 in.




Install the square cut c-ring.





CAUTION: Be sure the scribe marks are aligned.

Install the compressor housing and v-band clamp.

Torque Value: 8 N-m [72 in-lbs]

NOTE: Apply anti-seize compound to the V-band bolt threads. Tighten the clamp to the specified torque. Tap against the clamp on 4 places around its circumference. Again tighten the clamp to the specified torque.