ISM, ISMe, and QSM11 – 010-033   Turbocharger

WARNING  This component weighs 23 kg [50 lb] or more. To avoid personal injury, use a hoist or get assistance to lift this component.

CAUTION  When installing the lifting eye, make sure the shoulder of the lifting eye is bottomed against the bearing housing. Failure to do so can result in failure of the lifting eye and personal injury.

CAUTION  If the lifting eye is installed in the turbocharger bearing housing, it is to be used exclusively for turbocharger removal and installation. It is not to be used in removal of the exhaust manifold, or engine. Doing so will cause damage the turbocharger.

CAUTION  The turbocharger actuator must not be used as a lifting mechanism. Doing so will cause damage to the turbocharger actuator.

Thread a lifting strap around the turbocharger bearing housing. Take care not to bend the coolant lines when lifting the turbocharger.

Care must be taken not to damage the turbocharger compressor inlet air temperature sensor, the turbocharger speed sensor, and the turbocharger actuator coolant lines when removing the turbocharger from the engine.

Remove the four turbocharger mounting nuts.

Remove the nuts from the turbocharger studs and remove the turbocharger.

NOTE: If the turbocharger mounting nuts do not loosen freely, split the nuts to avoid breaking a mounting stud.

Remove the turbocharger and discard the gaskets.

Cover the turbocharger exhaust inlet port with a cap from the Air Handling and Vehicle Air Plumbing Clean Care Kits, Part Number 4919403 and 4919425, respectively. Cover the opening on the exhaust manifold with heavy tape.

If the turbocharger is being replaced with a new turbocharger, remove the variable geometry turbocharger actuator.

Refer to Procedure 010-134 in Section 10.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

CAUTION  When installing the lifting eye, make sure the shoulder of the lifting eye is bottomed against the bearing housing. Failure to do so can result in failure of the lifting eye and personal injury.

CAUTION  If the lifting eye is installed in the turbocharger bearing housing, it is to be used exclusively for turbocharger removal and installation. It is not to be used in removal of the exhaust manifold, or engine. Doing so will cause damage the turbocharger.

CAUTION  The turbocharger actuator must not be used as a lifting mechanism. Doing so will cause damage to the turbocharger actuator.

NOTE: ISM CM870 and CM570 – The capscrew in the top of the turbocharger bearing housing can be removed and replaced with a lifting eye to aid in removal of the turbocharger.

Care must be taken not to damage the turbocharger compressor inlet air temperature sensor, the turbocharger speed sensor, and the turbocharger actuator coolant lines when removing the turbocharger from the engine.

Remove the four turbocharger mounting nuts from the turbocharger studs and remove the turbocharger.

NOTE: If the turbocharger mounting nuts do not loosen freely, split the nuts to avoid breaking a mounting stud.

Remove the turbocharger and discard the gaskets.

Remove the four turbocharger mounting nuts.

Remove the turbocharger and gasket.