104302-6440 ZEXEL 9 400 616 416 BOSCH INJECTION-PUMP ASSEMBLY 9400616416 1043026440 2801250103

Insert the special tool, Piston Ring Inserter to the turbine wheel and install the piston ring.(4) Installation of turbine wheel assembly Install using care not to damage the piston ring. After installation, turn the turbine wheel manually to check that it turns smoothly. If not, disassemble and reassemble again.(5) Installation of compressor wheel (a) Holding the center housing and turbine wheel shaft with fingers, insert slowly into the special tool, Holding Fixture. 1. When inserting, use care not to damage the turbine wheel assembly blades.2. Do not release the shaft before insertion as otherwise the turbine wheel assembly will drop. (b) After tightening the lock nut to specified torque, tighten additionally 110° using special tool, T-handle. Use care not to bend the shaft of turbine wheel assembly.(6) Installation of turbine housing Apply MOLYKOTE to the turbine housing attaching bolt threads and tighten temporarily. Then align match marks and tighten to specified torque. Use care not to damage the turbine wheel assembly blades.(7) Inspection of shaft play [Refer to Item (1) and (2), Section 5.3.1.](8) Installation of compressor housing (a) Lay the compressor housing on the back plate and face the compressor housing downward.(b) Align match marks put at time of disassembly and tighten to specified torque.(9) After assembly, turn the turbine wheel and compressor wheel manually to check that they turn smoothly. If they turn heavily or irregularly, disassemble and check causes.5.4 TD07 Turbocharger
Disassembly
Disassembly Procedure(1) Removal of turbine housing If the turbine housing is hard to remove, tap the turbine housing on its periphery using a plastic hammer or similar tool. The turbine wheel blades are easy to bend. Use care not to damage them.(2) Removal of compressor cover Using a plastic hammer or the similar tool, tap the compressor cover on its periphery and remove. Be careful not to hit the compressor wheel against compressor cover as its blades are easy to bend.(3) Removal of compressor wheel (a) Fit the bearing housing into the turbine housing which is clamped in a vise. (b) Hold the boss on the turbine wheel and remove the lock nut that attaches the compressor wheel. (c) Slowly lift up the compressor wheel to remove it.(4) Removal of insert (a) Remove the snap ring holding the insert into the bearing housing. Retain the snap ring by hand to prevent it from springing out when slipping off the snap ring pliers. (b) Hook the tips of the screwdrivers to the insert at the positions shown in the illustration, then carefully pry up the insert and thrust sleeve as a unit to remove them.Inspection and cleaning
Inspection Procedure(1) Cleaning (a) Immerse disassembled parts in a nonflammable solvent (Daido Kagaku Kogyo's Dai Cleaner T-30 or equivalent) to clean oily contamination. When a commercially-available neutral detergent is used for cleaning, make sure that it does not contain corrosive component. (b) Blow compressed air against the entire internal and external surfaces. (c) Using a plastic scraper or bristle brush, remove deposits from the surfaces. Then, dip parts in the