Turbocharger

To remove

Operation 9-1

Warning! Turbochargers operate at high speed and at high temperatures. Keep fingers, tools and other

objects away from the inlet and outlet ports of the turbocharger and avoid contact with hot surfaces.

1  Thoroughly clean the turbocharger.

2  Remove the air cleaner hose at the compressor inlet.

3  Remove the hose from the compressor outlet.

4  Release the setscrews (A1) from the flange (A2) of the oil supply pipe (A4) at the top of the bearing housing.

5  Release the union nut / connection (A6) at the other end of the pipe on the oil filter head. Use a spanner to

hold the union (A5) on the filter head when the union nut is released.

6  Remove the pipe and discard the flange joint (A3).

7  Remove the setscrews (B7) from the flange (B2) of the oil drain pipe (B5) at the bottom of the bearing

housing.

8  Remove the setscrew (B4) and the clamp (B3), at the other end of the pipe.

9  Remove the oil drain pipe and discard its two ’O’ rings (B6) and flange joint (B1).

10  Hold the turbocharger and release the setscrews that retain the turbocharger to exhaust manifold. Remove

the turbocharger and discard the gasket.

11  Cover the openings in the manifolds and the pipes to ensure that debris will not enter.

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Peregrine EDi and 1300 Series EDi

To fit

Operation 9-2

1  Remove the covers from the pipes and manifolds.

2  Check that the turbocharger inlet and outlet are clean and free from restriction. Check that the turbocharger

shaft rotates freely. Also check that the openings in the manifolds and the exhaust pipe are clean and free from

restriction.

3  Fit a new gasket to the exhaust manifold to turbocharger flange.

4  Put the turbocharger in position and hold it. Fit and tighten the setscrews to 66 Nm (49 lbf ft) 6,7 kgf m.

5  Put a suitable container under the turbocharger to contain the oil from the oil drain outlet of the turbocharger.

3

6  Pour 140 cm  (0.25 pints) of clean engine lubricating oil into the oil supply port of the bearing housing.

7  Fit a new joint (A3) to the oil supply port on the top of the turbocharger.

8  Clean the threads of the union connection (A5 and A6) and apply a thread sealant to the union connection

(A5).

9  Put the oil supply pipe (A4) in position, fit, but do not tighten the flange setscrews (A1).

10  Use a spanner to hold the union connection (A5) while the union nut (A6) on the pipe is tightened.

11  Tighten the flange setscrews (A1).

12  Fit the air cleaner hose to the compressor inlet.

13  Fit the compressor outlet hose.

14  Fit a new joint (B1), the flange (B2) and two new ’O’ rings (B6) onto the oil drain pipe (B5).

15  Install the oil drain pipe into its port in the crankcase. Put and hold the flanged end of the oil drain pipe

against the oil drain port, at the bottom of the turbocharger.

16  Fit but do not tighten the two flange setscrews (B7).

17  Put the pipe clamp (B3) in position and hold it. Fit but do not tighten the setscrew (B4).

18  Tighten the three setscrews evenly and gradually.

19  Remove the container and dispose of the lubricating oil in a safe place in accordance with local regulations.

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Peregrine EDi and 1300 Series EDi

To dismantle

Operation 9-3

Note: The components of the rotating assembly and the components of the bearing housing, except the

backplate ’O’ ring, have been withdrawn as service items. If there is a failure of these components, or if they

are excessively worn, the complete bearing housing and rotating assembly must be renewed as a unit.

1  Remove the turbocharger from the engine, see Operation 9-1.

2  Put reference marks (A) on the compressor casing, on the backplate and on the turbine housing to ensure

correct assembly later.

3  Hold the turbocharger in a vice that is fitted with soft jaws to protect the turbocharger.

4  Remove the boost sensor pipe (B1) at the waste-gate actuator (B4). Remove the waste-gate actuator and

bracket assembly, see Operation 9-7.

5  Remove the six setscrews (B2) that hold the compressor casing (B3) to the backplate (C6), remove the three

lock plates.

6  Remove carefully the compressor casing from the turbocharger. If the casing is tight, hit it lightly with a soft

faced hammer.

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Continued

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Peregrine EDi and 1300 Series EDi

7  Remove the compressor housing seal (D7).

8  To change the angle of the compressor inlet, the casing must be removed completely and then fitted again.

Do not turn the casing while it is fitted to the turbocharger because the compressor housing seal will be

damaged.

9  Remove the six setscrews (D3) that hold the waste-gate housing (D4) to the turbine casing (D2) and remove

the waste-gate housing.

10  Remove the four setscrews (D1) that hold the bearing housing assembly (D5) to the turbine casing, remove

the bearing housing assembly.

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Peregrine EDi and 1300 Series EDi

To assemble

Operation 9-4

1  Fit the waste-gate housing (A4) to the turbine housing (A2), fit and tighten the six setscrews (A3).

2  Fit the bearing housing assembly (A5) to the turbine housing (A2) and align the marks (B). Fit and tighten

the four setscrews (A1) to 13,5 Nm (9.6 lbf ft) 1,3 kgf m.

3  Fit the compressor housing seal (A7).

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4  Fit the compressor housing to the backplate (A6) and align the marks (B). Fit the three lock plates and the

six setscrews (C2). Tighten the setscrews to 21/24 Nm (15.5/17.7 lbf ft) 2,14/2,44 kgf m.

Caution: To change the angle of the compressor inlet, the casing must be removed completely and then fitted

again. Do not turn the casing while it is fitted to the turbocharger because the compressor seal will be

damaged.

5  Check that the turbine rotates freely.

6  Fit the waste-gate actuator and bracket assembly, see Operation 9-7. Fit the boost sensor pipe.

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Peregrine EDi and 1300 Series EDi

To inspect

Operation 9-5