- Engine:Commercial All
- Machine Engines: All
- Truck Engines:Truck All
This special instruction provides the instructions for the installation of the turbocharger. Turbochargers are sensitive to contamination. Failure to follow any of the procedures may result in damage, a malfunction, or possible engine failure.
The following items have been made available to help reduce premature Turbocharger failure due to contamination.
- A magnetic cover SELD0271 has been placed over the oil inlet on the turbocharger.
- A quick reference Critical Requirements, REHS3033 has been attached to all turbochargers.
- An instruction manual for turbocharger failures has also been published in order to assist in diagnosing turbocharger failures. The document is Special Instruction, SEBF9085, “Failure Modes of Turbochargers”.
|The correct procedures and tooling specifications must always be used. Failure to follow any of the procedures may result in damage, malfunction, or possible engine failure.|
- Clean the area around the turbocharger in order to remove potential contaminants.
- Examine the turbocharger for potential causes of failure.
- If there is any damage to the turbine wheel, examine the exhaust system and the exhaust manifold to ensure that no foreign material remains.
- If there is any damage to the compressor wheel, examine the air cleaner, the aftercooler, and the ducting to ensure that no foreign material remains.
- If there is any sign of oil on the compressor side, inspect the accumulator/oil separator and the aftercooler.
|Oil that is left in the Air-To-Air Aftercooler can result in engine overspeed.|
- Work in an enclosed area or use tarps to minimize the entrance of airborne debris. Leave the SELD0271 magnetic cover in place over the oil inlet on the turbocharger. The cover will help prevent contamination during installation.
- The bolts in the turbochargers may be intentionally left loose in order to facilitate the installation. Extra bolts may be required.
Proceed to the Installation and Prelubing of the Turbocharger section if the following items are complete.
- The turbocharger compressor housing and the turbine housing are aligned.
- The bolts should be tight.
- All of the locking tabs should be bent upward.
Realignment of the End Housing
- Loosen the bolts for the turbocharger compressor housing and the bolts for the turbocharger turbine housing, and/or loosen the nuts on the V-band clamp. Excessive loosening of the housings will cause contact between the internal components of the turbocharger. Possible damage to the turbine wheel may occur.
- Temporarily secure the turbocharger to the output flange of the engine exhaust manifold. Ensure that the bolts are snug.
- Rotate the center housing so that the oil inlet and outlet ports will mate with the turbocharger oil supply line and oil drain line. The oil outlet must be at the bottom.
Note: If the turbocharger has a drain tube, use the drain tube to verify proper orientation of the bearing housing. The drain tube should be installed so that there is no binding of the tube after the installation. For turbochargers without a drain tube, the centerline of the hole must not be more than 35 degrees from vertical.
- Tighten at least two of the bolts or the V-band clamp in order to lock the center housing to the turbine housing.
- Rotate the compressor housing until the housing lines up with the intake manifold or the aftercooler outlet line. Tighten at least two of the bolts or the V-band clamp in order to lock the housing in place.
- Complete the following before you remove the turbocharger from the engine.
- Tighten all of the bolts or the nuts on the V-band clamp.
- Tighten the bolts alternately in order to prevent any cocking of the housings.
- Tighten the bolts to the recommended torque.
- When the V-band clamps are correctly positioned, tighten the nuts of the V-band clamp to the specified torque. Gently tap around the clamps. Tighten the clamps again to the specified torque.
Bolt Locking Tabs
Bend the locking tabs upward against a flat surface on each bolt head on the bolted housing. Bend the locking tabs in a direction which will tighten the bolt. The nuts of the V-band clamp are self-locking.
Installation and Prelubing of the Turbocharger
- Remove the old gasket from the mount of the exhaust manifold. Inspect the flange for cracks, erosion, and flatness. If necessary, replace the exhaust manifold.
- Clean the passages from the engine exhaust manifold and the passages from the air filter to the turbocharger.
- Install the turbocharger on the engine with all new gaskets and O-ring seals. Do NOT connect the compressor inlet and the oil supply line. Tighten the bolts attaching the turbocharger to the exhaust manifold to the torques specified in the Service Manual or the Operation and Maintenance Manual.Note: Use 5P-3931 Anti-Seize Compound on the nuts and threads before installation.
- Remove the SELD0271 magnetic cover and fill the oil inlet with clean engine oil. Spin the compressor wheel several times in order to lubricate the bearing. Place the SELD0271 magnetic cover on the oil inlet of the core of the turbocharger.
- Connect the oil drain outlet line. Refill the oil inlet with clean oil. Connect the oil supply line. Tighten and torque the oil supply lines using standard torque specifications.Note: If the compressor wheel CANNOT be spun freely or if there is rubbing, the reason MUST be determined and corrected BEFORE starting the engine. End housings that are not properly seated on the cartridge housing may cause rubbing.
- If the compressor wheel spins freely, connect the pipe from the outlet of the air filter to the inlet of the compressor. Tighten the connections to the torques that are specified in the Specification, “Turbocharger” or the Operation and Maintenance Manual.
- Perform the following procedures to the oil bypass valve.
- First, remove the oil bypass valve.
- Then, inspect and clean the oil bypass valve.
- Finally, reinstall the oil bypass valve.
Note: If debris is found on the oil bypass valve, the oil pan must be removed and any debris must be cleaned from the oil pan. If the remaining debris is not removed, the oil bypass valve will be recontaminated upon start-up.
- CHANGE THE ENGINE OIL AND THE FILTER(S).
- Check the oil level in the engine crankcase.
Starting the Engine
- Start the engine. Allow the engine to run at low idle until the engine reaches operating temperature.
- Inspect the turbocharger for oil leaks.
ReferenceRefer to Special Instruction, SEBF9085, “Turbocharger Failure Modes” for additional information on turbocharger failures.