A 615397 Force DECAL, PORT

Table 1
Required Tools
Tool Part Number Part Description Qty
A 4C-5597 Anti-Seize Compound 1
B - P-80 Emulsion Rubber
Assembly Lubricant 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g06210885
Illustration 2 g06210896
Ensure that turbocharger (8) is clean and free from damage. Inspect the turbocharger for wear. Refer to System Operation, Testing and Adjusting, "Turbocharger Inspect" for more information. If any part of the turbocharger is worn or damaged, the complete turbocharger must be replaced.
If necessary, follow Step 2a through Step 2b to install bracket (22) onto the cylinder block.
Position bracket (22) onto the cylinder block. Install bolts (23).
Tighten bolts (23) to a torque of 44 N m (32 lb ft).
If necessary, install studs (24) (not shown) to turbocharger (8). Tighten the studs to a torque of 18 N m (159 lb in).
Install turbocharger (8) onto bracket (22).
Install nuts (25) onto studs (24) (not shown) hand tight. Tighten the nuts to a torque of 44 N m (32 lb ft).
Position a new gasket (20) (not shown) and a new gasket (27) (not shown) onto tube assembly (14).
Position tube assembly (14) onto turbocharger (8) and the cylinder block.
Install bolts (21) and bolts (26). Tighten bolts (21) and bolts (26) to a torque of 22 N m (195 lb in).
Remove the plug from oil inlet port (31). Lubricate the turbocharger bearings with clean engine oil through the oil inlet port. Rotate the wheel of the compressor several times to lubricate the bearings.
Remove the plugs from tube assembly (16). Ensure that tube assembly (16) is clean and free from restriction. Replace any damaged components.
Position a new gasket (28) (not shown) onto turbocharger (8).
Install new O-ring seal (18) onto tube assembly (16).
Position tube assembly (16) onto turbocharger (8) and oil filter head (19). Loosely install bolts (13) to the tube assembly. Tighten nut (17) finger tight.
Install bolt (15) to the clamp for tube assembly (16).
Tighten bolts (13) to a torque of 22 N m (195 lb in).Tighten bolt (15) to a torque of 22 N m (195 lb in).Tighten nut (17) to a torque of 43 N m (32 lb ft).
Remove plug from hose assembly (12) and connection on turbocharger (8). Ensure that hose assembly (12) and the connection are clean and free from restriction. Replace any damaged components.
Position a new O-ring seal (29) (not shown) onto tube assembly (12).
Connect hose assembly (12) to the connection on turbocharger (8). Tighten tube nut for hose assembly (12) on turbocharger (8) to a torque of 43 N m (32 lb ft).
Illustration 3 g06209343
Illustration 4 g06209348
Use Tooling (B) to lubricate the new O-ring seal (10) and new O-ring seal (11). Install O-ring seal (10) and O-ring seal (11) onto adaptor (4). Install adaptor (4) to turbocharger (3).
Use Tooling (B) to lubricate new O-ring seal (6) (not shown). Install the O-ring seal onto air duct (5).
Install air duct (5) to turbocharger (8) and turbocharger (3).
Install bolts (7) to air duct (5). Tighten the bolts to a torque of 22 N m (195 lb in).
Ensure that elbow (1) is clean and free from wear and damage. If necessary, replace the elbow.
Use Tooling (A) to lubricate the Allen head bolt for V-band clamp (9). Position V-band clamp (9) onto turbocharger (8).
Use Tooling (A) to lubricate the Allen head bolt for V-band clamp (2). Position V-band clamp (2) onto elbow (1).
Position elbow (1) onto turbocharger (3) and turbocharger (8).
Tighten V-band clamp (2) and V-band clamp (9) finger tight. Ensure that the V-band clamps are seated correctly onto the turbochargers.
Tighten the Allen head bolt for V-band clamp (2) and Allen head bolt for V-band clamp (9) to a torque of 12 N m (106 lb in).
Connect the air inlet hose to the turbocharger and tighten the hose clamp securely.End By:
Install the exhaust elbow to the second stage turbocharger. Refer to Disassembly and Assembly, "Exhaust Elbow - Remove and Install" for the correct procedure.