B5.9G, B5.9LPG – Troubleshooting and Repair Manual – 010-033   Turbocharger

• Remove the air crossover tube, if used.
• Disconnect the charge air cooler hose.
• Disconnect the boost capsule actuator hose.
• Disconnect the intake and exhaust piping.

Disconnect the exhaust and charge air cooler piping.

Drain the engine coolant and disconnect the turbocharger coolant lines.

Remove the capscrews from the oil drain tube.

Disconnect the oil supply line.

NOTE: Engines built after June 1993 may use a copper washer in both ends of the turbocharger lubricating oil supply line. The washer should be replaced
whenever the line is removed.

Remove the intake manifold pressure supply line from the wastegate actuator.

Remove the turbocharger and gasket.

Clean the sealing surface. Inspect the sealing surface and mounting studs for damage.

NOTE: If the turbocharger is not to be immediately replaced, cover the opening to prevent any material from falling into the manifold.

Inspect turbocharger wastegate linkage, valve shaft, module, and pressure signal line.

Visually inspect the turbocharger impeller blades for damage. If the impeller is damaged, inspect the intake piping and filter element for damage.

Check or calibrate wastegate. Refer to Procedure 010-050 or refer to the Turbocharger Shop Manual, Bulletin Number 3810321.

Install a new gasket, and apply anti-seize compound to the mounting studs.

NOTE: Use only lead-free anti-seize compound compatible with oxygen sensors.

Install the turbocharger.

Use a new gasket and connect the oil drain tube.

Use a new gasket and connect the oil drain tube.

CAUTION  Lubricating oil is vital to the turbocharger life; therefore, clean engine oil must be added through the oil supply fitting anytime a new turbocharger is installed.

NOTE: New turbochargers must be prelubricated before start-up.

Pour 50 to 60 cc [2 to 3 oz] of clean engine oil into the oil supply fitting. Rotate the turbine wheel to allow the oil to enter the bearing housing.

Connect the oil supply line.

If required, loosen the snap ring and align the compressor housing with the turbocharger air outlet connection.

Install the wastegate actuator capsule actuator hose.

Install charged air cooler hose.

Install the air inlet and exhaust piping.

Fill the cooling system. Refer to Procedure 008-018.

Operate the engine and check for leaks.