Turbocharger Replacement

TM 9-2320-363-34-1 · Chapter 3 — Power Package Maintenance

This task covers: a. Removal b. Cleaning c. Inspection d. Installation

Tools and Special Equipment:                      Personnel Required: (2)
Shop Equipment, SC 4910-95-CL-A31                 General Safety Instructions:
Tool Kit, SC 5180-90-CL-N05
Torque Wrench Adapter, 11663358-2
Turbocharger Inlet Shield, J26554-A                               WARNING
                                                           Hot turbocharger and exhaust
Materials/Parts:                                           pipe can cause serious
Seal, Clamp             P/N KYX00-5833                     burns. Do not work on
                                                           exhaust system until it is
Gasket, Exhaust         P/N 8929529                        cool. To do so could result in
Inlet                                                      serious injury to personnel.
Gasket, Drain           P/N 8929285                         Turbocharger weighs 50 lb
Tube
                                                           (23 kg). Use two persons or
Oil, Engine             Appendix B, Item 37                suitable lifting device during
                                                           removal or installation to
Tape, Masking           Appendix B, Item 58                prevent personal injury or
                                                           damage to turbocharger.
                                                            Use turbocharger inlet shield
                                                           when servicing turbocharger.
                                                           Failure to do so could result
                                                           in serious injury to personnel
                                                           or damage to turbocharger.

1. REMOVE TWO BOLTS (1) AND SEAL CLAMP (2) FROM FLEX PIPE (3) AND OUTLET PIPE (4). DISCARD SEAL CLAMP.

2. REMOVE NUT (5) AND VEE CLAMP (6) FROM OUTLET PIPE (4) AND TURBOCHARGER (7).

3. LOOSEN CLAMP (8) AND REMOVE INTERCOOLER DUCT (9) FROM T TURBOCHARGER (7).

4. LOOSEN CLAMP (10), REMOVE AIR INLET DUCT (11) FROM TURBOCHARGER (7), AND INSTALL TURBOCHARGER INLET SHIELD.

5. DISCONNECT OIL SUPPLY LINE (12) FROM FITTING (13) ON TOP OF TURBOCHARGER (7).

6. REMOVE BOLT (14) AND WASHER (15) FROM OIL SUPPLY LINE CLIP (16) ON OIL FILTER ADAPTER UPPER MOUNTING LEG AND MOVE AWAY FROM TURBOCHARGER (7).

7. REMOVE TWO BOLTS (17) SECURING OIL DRAIN LINE (18) TO BOTTOM OF TURBOCHARGER (7).

8. REMOVE AND DISCARD GASKET (19).

9. REMOVE FOUR NUTS (20) AND FOUR WASHERS (21) SECURING TURBOCHARGER (7) TO EXHAUST MANIFOLD (22).

10. REMOVE TURBOCHARGER (7) AND GASKET (23). DISCARD GASKET.

11. TAPE ALL OPENINGS OF TURBOCHARGER (7).

Use general cleaning methods to clean all parts (page 2-30).

1. INSPECT TURBOCHARGER MOUNTING STUDS ON EXHAUST MANIFOLD FOR DAMAGE OR LOOSENESS.

2. REMOVE AND REPLACE DAMAGED STUD(S). TIGHTEN STUD(S), IF LOOSE. IF DAMAGED, REMOVE THREADED TURBOCHARGER STUD(S) BY UNSCREWING. USING TWO NUTS, ONEAS JAM NUT, THREAD NEW STUD(S) INTO EXHAUST MANIFOLD UNTIL UNTHREADED PORTION OF STUD IS BOTTOMED AGAINST MOUNTING FLANGE, TIGHTEN STUD(S) TO 18-24 LB-FT (25-32 N.m).

3. INSPECT ALL PARTS FOR WEAR OR DAMAGE.

Use turbocharger inlet shield when servicing turbocharger. Failure to do so could result in serious injury to personnel or damage to turbocharger.

1. REMOVE TAPE FROM ALL OPENINGS OF TURBOCHARGER (1) AND INSTALL TURBOCHARGER INLET SHIELD.

2. POSITION NEW GASKET (2) ON EXHAUST MANIFOLD TURBOCHARGER MOUNTING FLANGE STUDS (3).

Turbocharger weighs 50 lb (110 kg). Use two persons or suitable lifting device during installation to prevent personal injury or damage to turbocharger. I

3. PLACE TURBOCHARGER (1) ON MOUNTING FLANGE STUDS (3) WITH EXHAUST OUTLET SIDE (4) FACING TOWARD REAR.

4. INSTALL FOUR FLAT WASHERS (5) AND FOUR NUTS (6) ON MOUNTING FLANGE STUDS (3). TIGHTEN NUTS TO 43-54 LB-FT (58-73 N.m).

5. INSTALL NEW GASKET (7) AND CONNECT OIL DRAIN LINE (8) TO BOTTOM OF TURBOCHARGER (1) WITH TWO BOLTS (9). TIGHTEN BOLTS TO 22-28 LB-FT (30-38 N.m).

6. CAREFULLY POUR HALF-PINT OF ENGINE LUBRICATING OIL INTO OIL INLET PORT (10) AT TOP OF TURBOCHARGER (1) WHILE MANUALLY ROTATING TURBOCHARGER COMPRESSOR WHEEL. CONNECT OIL SUPPLY LINE (11) AND REMOVE SPILLED OIL FROM TURBOCHARGER (1) AND EXHAUST MANIFOLD.

7. REMOVE TOP OIL FILTER ADAPTER MOUNTING BOLT (12) AND WASHER (13), INSTALL OIL SUPPLY LINE CLIP (14) ON OIL FILTER ADAPTER AND INSTALL WASHER (13) AND BOLT (12). TIGHTEN BOLT TO 43-54 LB-FT (58-73 N.m).

8. REMOVE TURBOCHARGER INLET SHIELD AND INSTALL AIR INLET DUCT (15) ON TURBOCHARGER (l). TIGHTEN CLAMP (16) TO 18-22 LB-FT (24-30 N.m).

9. INSTALL INTERCOOLER DUCT (17) ON TURBOCHARGER (l). TIGHTEN CLAMP (18) TO 18-22 LB-FT (24-30 N.m).

10. INSTALL VEECLAMP (19) AND NUT (2O) BETWEEN OUTLET PIPE (21) AND TURBOCHARGER (l). TIGHTEN NUT TO 18-22 LB-FT (24-30 N.m).

11. INSTALL NEW SEAL CLAMP (22) AND TWO BOLTS (23) BETWEEN FLEX PIPE (24) AND OUTLET PIPE (21 ). TIGHTEN TWO BOLTS TO 18-22 LB-FT (24-30 N.m).