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Turbocharger Removal & Installation Guidelines
These instructions apply to all turbochargers. They are in addition to professional instructions, NOT a substitute. When installing a replacement turbocharger, be certain there is no foreign material in the air cleaner and the ducting to the compressor interior in the exhaust manifold. Even small or soft objects will cause extensive damage to the turbocharger wheels. Take care to avoid getting dirt or debris into the turbocharger openings. New and replacement turbochargers may have bolts missing or deliberately left loose to facilitate installation. (A bolt kit, not supplied by MAP, may be required. If the turbocharger bolts are all tight, all lock tabs bent up and the compressor and turbine housings are correctly aligned proceed to Step IV. Otherwise, proceed to Step II.
Loosen the compressor (aluminum) and turbine (cast iron) housing bolts and / or V-band nut(s) the minimum required to permit the housings to rotate on the center housing. Excessive loosening of the housings will allow contact and possible wheel damage. Bolts should not have to be loosened more than 1 1/2 turns. Temporarily secure the turbocharger to the engine exhaust manifold outlet flange with two bolts. Rotate the center housing, so that the oil inlet and outer pads will mate with the engine lines. The oil outlet (large hole) must be at the bottom with the centerline of the hole not more than 35° from vertical. Snugly tighten at least two bolts on the V-band to lock the housing in place. Rotate the compressor housing, until it lines up with the intake manifold or intercooler ducting. Snugly tighten at least two bolts or V-band to lock the housing in place. Remove the turbocharger from the engine and tighten all bolts and/or V-band nuts. Tighten the bolts alternately from side to side to prevent cocking of the housing. Turn the V-band nuts slowly as the torque setting is approached, (tapping the band slightly with a soft mallet), to allow for the band to fully seat. Refer to the torque valves specified in the applicable manual.
T3 automotive 165 in./lbs.
Compressor (GT Series) 145-165 in./lbs.
Turbine (GT Series) 185-215 in./lbs.
Compressor and Turbine (Navistar) 185-215 in./lbs.
All other models 140 in./lbs.
Bend lockplate tabs up against a flat on each bolt head (if not already bent) on bolted housing models. Bend in a direction that will tend to tighten, not loosen, the B-band nuts are self-locking.
Remove the old gasket from the exhaust manifold-mounting flange, inspect flange for erosion and flatness, and install a new gasket, if used. Inspect oil drain and supply lines for kinking, clogging, restrictions, and other signs of deterioration. *Replacing the oil feed line is a requirement to validate your warranty*. Install the turbocharger on the engine using all new gaskets and o-rings (when needed), but do not connect the compressor inlet and oil supply line. Tighten the nuts or bolts attaching the turbocharger to the exhaust manifold to the torque values giving in the shop manual. Use of a high-temperature lubricant on these threads is recommended. Fill the oil inlet hole with clean engine oil and spin the compressor wheel several times to coat the bearings with oil. Refill the oil inlet hole and connect the oil supply line. If the compressor wheel cannot be freely spun by hand or if there is any indication of rubbing or scraping, determine the reason before starting the engine. One cause of wheel rubbing is a cocked compressor or turbine housing. T04 and T04B turbochargers may have a slight drag before running, which is a normal condition. Connect the pipe or hose from the outlet of the air filter to the compressor inlet. Check lubricant level in engine crankcase. Prime the oil filter if it was changed.