SECTION D Fuel Charging and Controls Turbocharger

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1 303-04D-i Fuel Charging and Controls Turbocharger D-i SECTION D Fuel Charging and Controls Turbocharger CONTENTS PAGE Turbocharger D-2

2 303-04D-2 Fuel Charging and Controls Turbocharger D-2 Turbocharger Special Tool(s) General Equipment Light-duty 3 inch C-clamp 2-Jaw Puller 205-D035 (D81L-1002-A) or equivalent Air Crossover Seal Installers Material Item SAE 15W-40 Super Duty Diesel Motor Oil XO-15W40-QSD (US); CXO-15W40-LSD12 (Canada); or equivalent Disassembly Specification WSS-M2C171-E 1. Remove the turbocharger crossover tube. Impact Slide Hammer (T50T-100-A) Low-Pressure Turbocharger to High-Pressure Turbocharger Press NOTE: The seals in the turbocharger crossover tube are one-time-use seals and must be installed new every time the connection is disassembled. NOTE: Large remover shown, small remover similar. Turbocharger Lifting Bracket Position the crossover tube in a soft-jawed vise. Using the special tool, remove the turbocharger crossover seal from each end of the crossover tube. Universal Handle (T80T-4000-W) 3. Remove the turbocharger tube.

3 303-04D-3 Fuel Charging and Controls Turbocharger D-3 Remove the nut and disconnect the turbocharger actuator linkage. Turbocharger with press-fit linkage 4. NOTE: Remove the turbocharger actuator only if the high-pressure turbocharger is being serviced. NOTE: It will be necessary to position the linkage to gain access to the clip. A section of rubber hose can be used to hold the linkage in position while removing the clip. 7. Remove the bolts and the turbocharger actuator. Remove the clip for the turbocharger actuator linkage. 8. Remove the turbocharger actuator insulator. 5. Using the special tool, disconnect the turbocharger actuator linkage. 9. Measure the gap between the 2 turbochargers prior to separating them and record the gap. Using an appropriate tool, carefully separate the 2 turbochargers. Turbocharger with slip-fit linkage 6. NOTE: Remove the turbocharger actuator only if the high-pressure turbocharger is being serviced.

4 303-04D-4 Fuel Charging and Controls Turbocharger D Remove and discard the low-pressure to high-pressure turbocharger seal and gasket. Assembly 1. NOTE: Install a new O-ring seal on the turbocharger oil supply standoffs. If necessary, install the turbocharger oil supply standoffs. Tighten to 47 Nm (35 lb-ft). 11. NOTE: The seal in the turbocharger is a one-time-use seal and must be installed new every time the connection is disassembled. Using the special tool, remove the low-pressure turbocharger tube seal from the turbocharger. 2. Using the special tools, install the low-pressure turbocharger tube seal in the turbocharger. 12. If necessary, remove the turbocharger oil supply standoffs. Remove and discard the O-ring seal. 3. Install a new low-pressure to high-pressure turbocharger seal and gasket.

5 303-04D-5 Fuel Charging and Controls Turbocharger D-5 NOTE: The turbochargers do not go flush together. Remove the tool when the gap equals the measurement taken during the disassembly. Using the special tool, assemble the turbocharger assembly. Tighten to 17 Nm (150 lb-in). 4. NOTICE: The washers must be installed with the convex and concave surfaces facing towards each other. Failure to install the washers correctly may result in damage to the tool. NOTE: Prior to installing the special tool, assemble the turbochargers by hand. Verify that the turbocharger assembly goes back together evenly. Install the special tool and loosely install the nuts. 6. NOTICE: Failure to use the turbocharger lifting bracket during removal, handling or installation of the turbocharger could result in a low-pressure to high-pressure turbocharger seal failure. Install the special tool and bolts. Tighten to 20 Nm (177 lb-in). 7. Position the turbocharger actuator insulator. 5. NOTICE: Do not over-tighten the nuts or damage to the special tool may occur. NOTE: A block of wood may be used to level the turbocharger during assembly of the turbochargers.

6 303-04D-6 Fuel Charging and Controls Turbocharger D-6 8. Install the turbocharger actuator and bolts. Tighten to 19 Nm (168 lb-in). Turbocharger with slip-fit linkage 9. Position the turbocharger actuator linkage and install the nut. 12. NOTE: Lubricate the seal with clean engine oil prior to assembly. Install the turbocharger tube. Tighten to 8 Nm (71 lb-in). 13. NOTE: Large installer shown, small installer similar. Turbocharger with press-fit linkage 10. Using a light-duty 3 inch C-clamp and a socket, install the turbocharger actuator linkage. Position the crossover tube in a soft-jawed vise. Using the special tool, install a new seal in each end of the turbocharger crossover tube. 11. Install the clip for the turbocharger actuator linkage. 14. Install the turbocharger crossover tube.

7 303-04D-7 Fuel Charging and Controls Turbocharger D-7

IN-VEHICLE REPAIR. Oil Pan Lower. Removal. 2. Disconnect the LH and RH battery ground cables. For additional information, refer to Section

IN-VEHICLE REPAIR. Oil Pan Lower. Removal. 2. Disconnect the LH and RH battery ground cables. For additional information, refer to Section 303-01C-1 IN-VEHICLE REPAIR Oil Pan Lower Special Tool(s) 3-Bar Engine Support 303-F070 Lifting Eyes 303-D030 303-01C-1 2. Disconnect the LH and RH battery ground cables. For additional information, refer