808001A 1 Mercruiser FITTING ASSEMBLY

2. Remove bolts (1) and nuts, then remove aftercooler to turbocharger air pipe (3).3. Remove bolts (2) and nuts, then remove air cleaner to turbocharger air pipe (4). 4. Remove bolts (5), then remove turbocharger supply and drain lines (6). 5. Remove bolts (8), then make a separation between turbocharger (7) and support. Remove turbocharger (7).Install Turbocharger
1. Put gasket (2) and turbocharger (1) in position on exhaust manifold support.2. Put 9M3710 Anti-Seize Compound on the bolts that hold turbocharger to exhaust manifold support. Install the bolts and tighten them to a torque of 40 5 lb.ft. (55 7 N m). 3. Install turbocharger supply line (4) with the bolts (3) that hold it.4. Install turbocharger drain line (5) with the bolts that hold it. 5. Install new O-ring seals (8) on air pipes (7) and (9). Install air cleaner to turbocharger air pipe (9) with four bolts (6) and nuts.6. Install aftercooler to turbocharger air pipe (7) with the four bolts and nuts that hold it.7. Install left or right side hood group.Disassemble Turbocharger (Airsearch TV81 And TW81)
start by:a) remove turbocharger 1. Install turbocharger in tool group (A). Put marks on the three housings of the turbocharger for correct installation and alignment at assembly. Remove "V" clamp (2) and compressor housing (1). 2. Remove "V" clamp (3). Remove the cartridge housing (5) from the turbine housing (4). 3. Install tool (C) in tool (B) and put the cartridge assembly in tool (C) as shown. Use tool (D) to remove the nut that holds compressor wheel (6).
When the nut is loosened, do not put a side force on the shaft.
The oil used to heat the compressor wheel must have a flash point (the temperature at which the oil will burn) above 400°F (204°C).
4. Install tool (H) on tool (E). Heat tool (E) to 350°F (177°C). Install the cartridge assembly on tool (H) so that only the compressor wheel is in the oil. Heat the compressor wheel for no more than 10 minutes.
Do not let the turbine wheel hit the bottom of the press.
5. Install tool (H) on tool (G). Put the cartridge assembly in tool (H) as shown. Remove compressor wheel (6) with an arbor press and tool (F). Step 5 must be done before the compressor wheel becomes cooler. 6. Put the turbine wheel in tool (C). Remove seal ring (8) and shroud (7) from the shaft. 7. Bend the tabs of the locks from bolts (10) and remove the bolts and locks.8. Remove backplate assembly (11) from the cartridge housing. Remove spacer (9) from backplate assembly (11). Remove the seal rings from spacer (9).9. Remove the collar from behind backplate assembly (11). 10. Remove thrust bearing (13) and O-ring seal (12) from the cartridge housing. 11. Remove top bearing (14) and the washer from the cartridge housing. Put a long dye mark on the top face of bearing (14). 12. Use tool (J) and remove the two rings that hold top and bottom bearings in position. Remove the bottom bearing and washer. Put a short dye mark on the bearing. The dye marks are used for identification of the bearings when they are installed.13. Use tool (J) and remove the last ring that holds the bottom bearing in position from the cartridge housing.14. Check all the parts of the turbocharger for damage. If the parts have damage, use new parts for replacement. See SPECIAL INSTRUCTION FORM NO. SMHS6854 for TURBOCHARGER RECONDITIONING. Also see GUIDELINE FOR REUSABLE PARTS FORM NO. SEBF8018.Assemble Turbocharger (Airesearch TV81 And TW81)
1. Make sure that all of the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material.2. Put clean engine oil on all parts of the cartridge assembly.
Rings (1), (4) and (5) must be installed with the round edge of the rings toward the bearings.
3. Install ring (4) in the cartridge housing with tool (A).4. Install washer (3) and bearing (2) in the cartridge housing. Make sure the short dye mark on bearing (2) is up.5. Install rings (1) and (5) in the cartridge housing with tool (A). 6. Install tool (D) in tool (C). Install turbine shaft (6) in tool (D). Install seal ring (7) and shroud (8) on turbine shaft (6). Put 4L7464 Silicone Grease in the groove for seal ring (7) at assembly to one half or more of the depth of the groove all the way around.7. Install turbine shaft (6) in the cartridge housing.
Make sure the seal ring on turbine shaft (6) is fitted correctly in the cartridge housing.
8. Install washer (12), bearing (11) with the long dye mark up, thrust washer (10) with the three lubrication grooves up and O-ring seal (9) in the cartridge housing. 9. Install the seal rings on spacer (13). Install spacer (13) in backplate assembly (15). Make sure the chamfer end of spacer (13) is toward the inside of the cartridge assembly when the backplate assembly is installed.10. Install collar (14) and backplate assembly (15) on the cartridge assembly with the oil hole in the backplate assembly in alignment with the oil hole in the cartridge housing. 11. Install the locks and bolts (16) that hold backplate assembly (15) in position. Tighten the bolts to a torque of 90 10 lb.in. (10.2 1.1 N m).12. Use tool (B) to heat the compressor wheel in oil for no more than 10 minutes. The temperature of the oil must be 350°F (177°C). 13. Immediately after the compressor wheel is removed from the oil, put the wheel on the turbine shaft. Install the nut on the end of the shaft. Use a torque wrench and a universal socket of the correct size to tighten the nut to a torque of 150 lb.in. (16.9 N m) as shown.