Volvo 2003T Service Manual download pdf (Page 39)

Turbo compressor

Bearings

16. Check the bearings for abnormal wear and tear or

discolouration, and replace them where necessary.

Check the internal and external diameters of all bear-

ings. The external diameter should not be less than

12.31 mm (0.48464 in), the internal diameter should

not be more than 8.04 mm (0.31653 in).

Bearing Housing

17. Check the housing for corrosion or cracks. Check

measurements (D) and (E), and replace the housing

where necessary. Measurement (D) should not be

more than 12.42 mm (0.48897 in), measurement (E)

should not be more than 15.05 mm (0.59251 in).

Cover

18. Check measurements (F) and (G), and replace the

cover where necessary. Measurement (F) should not

be more than 12.45 mm (0.49015 in), measurement

(G) should not be more than 10.05 mm (0.39566 in).

Packing Rings

19. Check the packing rings to see if they are worn or

out of shape, and replace them with new ones where

necessary.

Reassembly

Grease all removable parts when reassembling them.

Position the circlips in the bearing housing so that the

openings in them are facing towards the oil outlet.

Mount the packing ring on the turbine shaft. Turn the

opening in the ring so that it is facing towards the oil

intake. Position the heat shield on the bearing casing,

and then place the turbine axle in the bearing housing.

Mount the bushing on the turbine shaft. Grease in the

compressor bearing with engine oil, and mount it on

the bearing casing, using new screws and washers to

fasten it. The torque should be 1.3 Nm±0.1(0.95 ft.lbs)

Tighten the screws to the above torque, then loosen

them a quarter turn before tightening them up to the

correct torque again. Position the two packing rings on

the oil deflector.

NOTE! The opening in the inner ring should be facing

the oil outlet, that in the outer ring should be facing

the oil intake.

The thickness of the sealant should be about

0.1-0.2mm (0.0039-0-0078 in). Fit the cover on the bear-

ing housing, and fasten it with new screws and washers.

The torque should be 1.3 Nm±0.1 (0.95 ft.lbs)

Position the oil deflector in the cover. Smear the edges

of the bearing housing which come in touch with the

cover, using Permatex for the purpose.Tighten the

screws to the above torque, then loosen them a quarter

turn before tightening them up to the correct torque

again. Position the compressor wheel on the turbine

shaft and fasten it with the left-hand thread nut. The

torque should be 2.0 Nm±0.1 (1.47 ft.lbs).

Mount the turbine housing on the bearing housing ac-

cording to the line-up marks. Screw the locking cover

into position, making sure that the screws used are not

those for the compressor housing. The torque should be

11.0 Nm±0.5 (M6), 26.0±1.0 (M8). Smear the edges of

the bearing housing where it comes in touch with the

compressor housing, using Permatex for the purpose.

The thickness of the sealant should be about 0.1-0.2

mm (0.0039-0-0078 in). Then mount the compressor

housing according to the line-up marks, and screw the

locking cover into position.

The torque should be 4.5 Nm±0.5 (3.32 ft.lbs).

Check the axial and radial clearance. Maximum permis-

sible axial clearance is 0.09 mm (0.00354 in), maximum

permissible radial clearance is 0.17 mm (0.00669 in).

Fitting the Turbo-Compressor

Before fitting the turbo-compressor on the engine, spray

clean engine oil into the oil intake, and turn the turbine

shaft so that the oil is evenly distributed. Clean the

turbo-compressor’s delivery and return oil lines. Change

the engine oil and the filter for the lubricant. Be sure to

use the correct quality of oil (see under “Technical

Data”). Oil changes should be carried out in accordance

with the instructions in the Manual, in order to keep the

engine clean. Clean the air filter.

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Volvo 2003T Service Manual Page 39

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