M11 Series – Service Manual – 010-033   Turbocharger

Remove the intake and exhaust pipes from the turbocharger.

Remove the oil supply line from the turbocharger.

Remove the oil drain line from the turbocharger.

NOTE: Some engine applications use water-cooled turbochargers.

If a water-cooled turbocharger is used, drain the cooling system, and remove the water supply and return lines from the turbocharger.

Remove the v-band clamp, discharge elbow, and o-ring from the turbocharger compressor discharge outlet.

Remove the four turbocharger mounting nuts.

Remove the turbocharger and gasket.

Clean the turbocharger and exhaust manifold gasket surfaces.

Inspect the turbocharger and exhaust manifold gasket surfaces, and mounting studs for cracks or damage.

CAUTION  A charge air cooler failure can cause progressive damage to the turbine housing.

Inspect the turbine and compressor housings.

If cracks that go all the way through the outer walls are found, the housing must be replaced.

If the turbine housing is damaged, check the charge air cooler. Refer to Procedure 010-027.

Cracks in the mounting flange longer than 15 mm [0.6-in] are not acceptable.

Cracks of any length that reach mounting holes are not acceptable.

Two cracks must be separated by at least 6.4-mm [0.25-in].

Cracks of any length that extend through the divider are acceptable only if they are separated by at least 12.5-mm [0.50-in].

If the engine experiences a turbocharger failure or where oil or debris are put into the charge air system, the charge air system must be inspected and cleaned. Refer to Procedures 010-027 and 010-023.

NOTE: The torque values given have been established using anti-seize compound as a lubricant.

Apply a film of high temperature anti-seize compound to the turbocharger mounting studs.

Use a new gasket and install the turbocharger.

Install and tighten the four mounting nuts.

Install the discharge elbow, v-band clamp, and new o-ring seal on the turbocharger compressor discharge outlet.

Tighten the clamp.

NOTE: Some engine applications use water-cooled turbochargers.

If a water-cooled turbocharger is used, install the water supply and return lines to the turbocharger.

Install and tighten the turbocharger oil drain line.

Pour 50 to 60 cc [2.0 to 3.0 ounces] of clean 15W-40 engine oil in the turbocharger oil supply line fitting.

Install and tighten the turbocharger oil supply line.

Install the intake pipe and tighten the clamp.

Install the exhaust pipe and tighten the clamp.

If a water-cooled turbocharger is used, fill the cooling system. Refer to Procedure 008-018.

Operate the engine and check for air leaks.

Compare the assembly number (1) on the turbocharger data tag with the turbocharger specified in the engine control parts list (CPL) number (2) listed on the engine dataplate.

If the correct turbocharger was not installed, remove it, and install the correct turbocharger.