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1106 Perkins motor - Turbocharger (Repair operations)

Removal Procedure (Side Mounted)

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. Disconnect the air hose for the turbocharger inlet and for the turbocharger outlet. If the turbocharger has a remote wastegate solenoid, disconnect the hose to the solenoid from the turbocharger. Disconnect the exhaust pipe. If the turbocharger has an exhaust elbow, remove the exhaust elbow.



Follow Steps to remove the tube assembly (4) for the oil feed. Remove the setscrew (5). Remove the banjo bolt (1) and remove the two sealing washers (2). Discard the sealing washers. Remove the tube assembly (3) from the cylinder block. Remove the O-ring seal (4) from the tube assembly. Discard the O-ring seal. Plug the port for the oil feed to the turbocharger with a suitable plug. Remove the tube assembly (10) for the oil drain. Remove the two setscrews (11). Remove the two setscrews (8) and remove the tube assembly (10) from the turbocharger (6). Remove the joint (7) and remove the joint (9). Discard the joints.



Remove the four nuts (15) from the turbocharger (6) and remove the turbocharger (6) from the exhaust manifold (12). Ensure that the weight of the turbocharger is supported as the nuts are loosened. Remove the joint (14). Discard the joint. If necessary, remove the four studs (13) from the exhaust manifold (12).

Removal Procedure (Top Mounted)

Disconnect the air hose for the turbocharger inlet and for the turbocharger outlet. If the turbocharger has a remote wastegate solenoid, disconnect the hose to the solenoid from the turbocharger. Disconnect the exhaust pipe. If the turbocharger has an exhaust elbow, remove the exhaust elbow.



Remove the two setscrews (5) in order to disconnect the tube assembly (4) from the cylinder block. Remove the joint (3). Discard the joint. Remove the setscrew (8) in order to disconnect the tube assembly (7) from the cylinder block. Remove the fasteners for the tube clips (2). Loosen the four nuts (11). Refer to Illustration. Remove the exhaust manifold (1) and the assembly of the turbocharger from the cylinder head.



Remove the banjo bolt (9) and remove the tube assembly (7) for the oil feed from the turbocharger (12). Remove the two sealing washers (10). Discard the sealing washers. Remove the O-ring seal (6) from the tube assembly (7). Refer to Illustration. Discard the O-ring seal. Remove the two setscrews (14) and remove the tube assembly (4) for the oil drain from the turbocharger (12). Remove the joint (13). Discard the joint. Remove the four nuts (11) and remove the turbocharger (12) from the exhaust manifold (1). Remove the joint (15) from the exhaust manifold (1). Discard the joint. If necessary, remove the four studs (16) from the exhaust manifold (1).

Disassemble and Assemble Procedures

Disconnect the pipe for the boost sensor (7) at the actuator (6). Remove the circlip (1) that retains the actuator rod (4). Remove the actuator rod (4) from the pin (2). Remove the nuts (5) from the bracket (3). Remove the actuator (6) from the bracket (3). Do not attempt to disassemble the turbocharger cartridge assembly or wastegate. Do not remove the compressor wheel. The turbocharger cartridge assembly and the wastegate are not field serviced, and should be replaced only as a unit.

Install the actuator (6) to the bracket (3). Install the nuts (5) to the bracket (3). Tighten the nuts to a torque of 5 Nm (44 lb in). Connect the bottom of the actuator (6) to a suitable air supply with an accurate gauge. Operate the arm of the actuator by hand in order to check that the valve is free to move. Push the arm of the wastegate valve toward the actuator (6) and hold the arm in position. Slowly apply air pressure to the actuator (6) until the pin (2) will fit into the actuator rod (4). Install the circlip (1) into the groove in the pin (2). Do not apply an air pressure of more than 205 kPa (29 psi) to the actuator. High pressures may damage the actuator. Install the pipe for the boost pressure (7) to the actuator (6).

Installation Procedure (Side Mounted)



Ensure that the turbocharger is clean and free from damage. Inspect the turbocharger for wear. If any part of the turbocharger is worn or damaged, the complete turbocharger must be replaced. Test the wastegate actuator (19) for correct operation. If the wastegate actuator is damaged or the wastegate actuator does not operate within the specified limits, the wastegate actuator must be replaced.

Clean the mating surfaces of the exhaust manifold (12). If necessary, install the four studs (13) to the exhaust manifold. Tighten the studs to a torque of 18 Nm (13 lb ft). Install a new joint (14) to the exhaust manifold (12). Position the turbocharger (6) on the exhaust manifold. Ensure that the turbocharger is correctly oriented. Install the four nuts (15). Tighten the nuts to a torque of 44 N·m (32 lb ft). If a new turbocharger is installed, the bearing housing (18) and the compressor housing (20) must be oriented to the correct positions.

Loosen the two band clamps (21) sufficiently in order to allow the housings to rotate. If the band clamps are damaged, replace the band clamps. Carefully turn the bearing housing (18) until the port for the oil feed (17) is upward. Rotate the compressor housing (20) until the compressor outlet is in the correct position. Ensure that the band clamps (21) are correctly oriented. Tighten the band clamps finger tight.

Ensure that the tube assemblies (3) and (10) are clean and free from damage. Replace any damaged components. Position a new joint (7) and the two setscrews (8) onto the tube assembly (10). Install the tube assembly (10) to the turbocharger (6). Tighten the setscrews (8) finger tight. Position a new joint (9) between the flange of the tube assembly (10) and the cylinder block. Install the two setscrews (11) finger tight. If a new turbocharger has been installed, check that the orientation of the bearing housing (18) is correct. If the orientation of the bearing housing is not correct, rotate the bearing housing until the tube assembly (10) fits correctly. Tighten the two band clamps (21) to a torque of 13 Nm (9.6 lb ft). Tighten the setscrews (8) and (11) to a torque of 22 Nm (16 lb ft).

Remove the plug from the oil inlet port (17). Lubricate the turbocharger bearings with clean engine oil through the oil inlet port. Rotate the wheel of the compressor several times in order to lubricate the bearings. Use Tooling in order to lubricate a new O-ring seal (4). Install the O-ring seal (4) to the tube assembly (3). Install the banjo bolt (1) and two new sealing washers (2) to the tube assembly (3). Install the tube assembly (3) to the cylinder block and to the
turbocharger (6). Tighten the banjo bolt (1) finger tight.

Install the setscrew (5) finger tight. Ensure that the tube assembly (3) fits correctly. Tighten the banjo bolt (1) to a torque of 20 Nm (14 lb ft). Tighten the setscrew (5) and (11) to a torque of 22 Nm (16 lb ft). If the turbocharger has an exhaust elbow, install the exhaust elbow. Connect the exhaust pipe. If the turbocharger has a remote wastegate solenoid, connect the hose for the solenoid to the turbocharger. Connect the air inlet hose and connect the air outlet hose to the turbocharger.

Installation Procedure (Top Mounted)

Ensure that the turbocharger is clean and free from damage. Inspect the turbocharger for wear. If the turbocharger is worn, the complete turbocharger must be replaced. Test the wastegate actuator (19) for correct operation. If the wastegate actuator is damaged or the wastegate actuator does not operate within the specified limits, the wastegate actuator must be replaced. Clean the mating surfaces of the exhaust manifold (1). If necessary, install the four studs (16) to the exhaust manifold. Tighten the studs to a torque of 18 Nm (13 lb ft). Support the exhaust manifold during installation of the turbocharger. Install a new joint (15) to the exhaust manifold (1).

Position the turbocharger (12) on the exhaust manifold (1). Install the four nuts (11). Tighten the nuts to a torque of 44 Nm (32 lb ft). If a new turbocharger is installed, the bearing housing (18) and the compressor housing (20) must be oriented to the correct positions. Loosen the two band clamps (21) sufficiently in order to allow the housings to rotate. If the band clamps are damaged, replace the band clamps. Carefully turn the bearing housing (18) until the port for the oil feed (17) is upward. Rotate the compressor housing (20) until the compressor outlet is in the correct position. Ensure that the band clamps (21) are correctly oriented. Tighten the band clamps finger tight.

Ensure that the tube assemblies (4) and (7) are clean and free from damage. Replace any damaged components. Position a new joint (13) and the two setscrews (14) onto the tube assembly (4). Install the tube assembly (4) to the turbocharger (12). Tighten the setscrews (14) finger tight. Remove the plug from the oil inlet port (17). Lubricate the turbocharger bearings with clean engine oil through the oil inlet port. Rotate the wheel of the compressor several times in order to lubricate the bearings. Install the banjo bolt (9) and two new sealing washers (10) to the tube assembly (7). Use Tooling in order to lubricate a new O-ring seal (6). Install the O-ring seal (6) to the tube assembly (7). Install the tube assembly (7) to the turbocharger (12). Tighten the banjo bolt (9) finger tight.

Install the exhaust manifold (1) and the assembly of the turbocharger to the cylinder head. Install the setscrew (8) finger tight. Ensure that the tube assembly (7) fits correctly. Position a new joint (3) between the flange of the tube assembly (4) and the cylinder block. Install the two setscrews (5) finger tight. If a new turbocharger has been installed, check that the orientation of the bearing housing (18) is correct. If the orientation of the bearing housing is not correct, rotate the bearing housing until the tube assemblies (4) and (7) fit correctly. Tighten the two band clamps (21) to a torque of 13 Nm (9.6 lb ft). Tighten the banjo bolt (9) to a torque of 20 Nm (14 lb ft). Tighten the setscrew (5) and (8) to a torque of 22 Nm (16 lb ft). Install the fasteners for the tube clips (2) to the cylinder block.
If the turbocharger has an exhaust elbow, install the exhaust elbow. Connect the exhaust pipe.

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