Disassembly and Reassembly

TURBOCHARGER

DISASSEMBLY AND REASSEMBLY

Disassembly Steps 1-8:

SERVICE POINTS OF DISASSEMBLY




5. REMOVAL OF SNAP RING
Place the compressor cover assembly on the floor with its end surface down and remove the snap ring with pliers.

CAUTION: During removal, hold with a finger the snap ring which can spring out.




6. REMOVAL OF CARTRIDGE ASSEMBLY
Remove the cartridge assembly by tapping the compressor cover with a soft hammer.

CAUTION: Some resistance will be experienced in the removal due to the O-ring on the cartridge assembly.

INSPECTION

TURBOCHARGER
1. Inspect the cast-iron turbine housing for damage, cracks, or evidence of contact between the turbine blades and the housing.
2. Manually open and close the waste gate valve to make sure it operates freely.
3. Inspect the turbine and compressor wheels for wear, damage, bent or broken blades.
4. Inspect the oil passage in the cartridge for signs of deposits or blockage.
5. Clean the inlet section of the compressor cover with a rag. Inspect it for signs of contact with the compressor turbine. If worn, replace it.

WASTE GATE ACTUATOR
1. Leak-test the waste gate valve actuator with a hand vacuum pump.
Replace the actuator if it does not hold vacuum.

2. Check the rod to see that it is not bent or binding.

SERVICE POINTS OF REASSEMBLY




7. INSTALLATION OF O-RING
Coat the inner surface of a new O-ring with a thin film of engine oil, and set it in the groove of the cartridge assembly.

CAUTION: Be careful not to damage the O-ring while installing it as oil leakage could result.




6. INSTALLATION OF CARTRIDGE ASSEMBLY
1. Coat the outer circumference of the cartridge assembly O-ring with a thin film of engine oil.
2. Install the cartridge assembly on the compressor cover by aligning the dowel pin.

CAUTION: When installing the cartridge assembly on the compressor cover, be careful not to damage the compressor wheel blades.




5. INSTALLATION OF SNAP RING
Place the cartridge assembly with the compressor cover faced down and install the snap ring.

CAUTION: Install the snap ring with the tapered side of its outside diameter up.




4. INSTALLATION OF TURBINE HOUSING
Install the compressor cover and cartridge assembly on the turbine housing with the dowel pin in alignment

Caution:
1. Be careful not to damage the blades of the turbine wheel.
2. Be careful to install the turbine housing in the correct direction.

TEST OF WASTE GATE ACTUATOR OPERATION




Using a tester, apply a pressure of approx. 76.7 kPa (11.1 psi) to the actuator and make sure that the rod moves.

CAUTION: Do not apply a pressure of more then 65.3 kPa (12.4 psi) to the actuator. Otherwise, diaphragm may be damaged. Never attempt to adjust the waste gate valve.