Turbocharger - Inspection

INSPECTION





Visually inspect turbocharger for excessive oil residue. Clean turbocharger if necessaryProcedures.

Visually inspect charge air cooler tubing for excessive oil residue. Clean charge air cooler tubing if necessary Charge Air Cooler And Hoses - Cleaning.

Visually inspect the turbocharger and exhaust manifold gasket surfaces. Replace stripped or eroded mounting studs.

1. Visually inspect the turbocharger for cracks. The following cracks are NOT acceptable:
- Cracks in the turbine and compressor housing that go completely through
- Cracks in the mounting flange that are longer than 15 mm (0.6 in.)
- Cracks in the mounting flange that intersect bolt through-holes
- Two (2) Cracks in the mounting flange that are closer than 6.4 mm (0.25 in.) together

2. Using a straight edge and feeler gauge, measure the flatness between the two longest sections of the turbocharger mounting flange. Specification is 0.1 mm ( 0.0039 in.) maximum.
3. Using a straight edge and feeler gauge, the exhaust manifold flange. Specification is 0.1 mm (0.0039 in.) maximum. The combined measurements of the turbocharger and the exhaust manifold flanges must not exceed the maximum spec of either of the two flanges. Example: if the turbocharger flange measured 0.005 mm and the exhaust manifold flange measures 0.005 mm then the spec
4. Visually inspect the impeller and compressor wheel fins for nicks, cracks, or chips. Note: Some impellers may have a factory placed paint mark which, after normal operation, appears to be a crack. Remove this mark with a suitable solvent to verify that it is not a crack.
5. Visually inspect the turbocharger compressor housing for an impeller rubbing condition. Replace the turbocharger if the condition exists.





6. Measure the turbocharger axial end play:
a. Install a dial indicator as shown. Zero the indicator at one end of travel.
b. Move the impeller shaft fore and aft and record the measurement. Allowable end play is 0.038 mm (0.00015 in.) MIN. and 0.093 mm (0.0037 in.) MAX. If the recorded measurement falls outside these parameters, replace the turbocharger assembly.










7. Measure the turbocharger bearing radial clearance:
a. Insert a narrow blade or wire style feeler gauge between the compressor wheel and the housing.
b. Gently push the compressor wheel toward the housing and record the clearance.
c. With the feeler gauge in the same location, gently push the compressor wheel away from the housing and again record the clearance.
d. Subtract the smaller clearance from the larger clearance. This is the radial bearing clearance.
e. Allowable radial bearing clearance is 0.33 mm (0.013 in.) MIN. and 0.50 mm (0.020 in.) MAX. If the recorded measurement falls outside these specifications, replace the turbocharger assembly.