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438 Task Descriptions

3.8.5 Exhaust turbocharger – Check

Spare parts
Designation / Use Part No. Qty.
Exhaust turbocharger
Bearing housing
Turbine housing
Compressor housing
Rotor
Compressor

Clean exhaust turbocharger (. Page 437).

Checking exhaust turbocharger

Item Findings Task

Visually check housing, guide vane • Cracks Replace

ring, heat shield and rotors for • Foreign objects
cracks, foreign objects and scoring. •Scoring
visible

Check oil supply bores in bearing Foreign objects visible. Replace

housing for foreign objects.

Check piston sealing faces and Damaged Replace

bearing points for damage.

Check turbine housing for scaling. Scale visible on gas inlet stay or Replace
circumference.

Check gas inlet flange and gas Flange uneven. • Rework: Smooth using
outlet flange for planeness. oilstone.
• Replace

Check rotors for bent or broken Damaged Replace

blades and check rotor shaft for
scored bearings.

Check piston seat in rear wall and •Scores Replace

bearing housing for scoring and • Damage
damage. visible

Self-locking nuts Replace

O-rings

Wear parts and rotating parts that display cracks must be replaced.

Replace clamping segments, nut, shaft nut, piston rings, cylinder head bolts and washers, O-rings, oil deflector,
thrust washer, snap rings, bearing bushes and screws during overhaul.

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Task Descriptions 439

Bearing housing

Note: The segment mating faces must not display severe corrosion.

1. Measure max. bore ID at the bearing points using a bore gauge.

• Max. bore ID = 22.272 mm
2. If the limit value is exceeded, replace bearing housing.

Turbine housing
1. Radial cracks of up to 10 mm in length in the area
of lug (2) and partition wall (1) are permissible.
2. Complete cracking is not permissible.
3. Slight scoring in the circumferential area is
permissible.
4. Replace component if the gas inlet flange or gas
outlet flange is distorted.

Compressor housing
1. Check circumferential area (arrowed) for scoring
and deformation. Scoring of up to 0,2 mm
is permissible.
2. Replace compressor housing if deformed.

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440 Task Descriptions

Rotor
1. Check rotor shaft for roundness:
1.1. Position rotor shaft on two prisms at the
bearing points.
1.2. Position probe on the shaft at a distance
of 5 mm to the end of the compressor
wheel seat.
1.3. Evenly press rotor shaft onto the prisms
during testing.
1.4. Maximum permissible out-of-round <
0.008 mm.
1.5. Replace rotor if the permissible out-of-round
is exceeded.
2. Measure shaft diameter at the bearing points and
piston ring groove width.
• Min. diameter = 14.25 mm
• Max. groove width = 3.32 mm
3. Replace shaft if out of tolerance.

Note: During production, all compressor wheels and

shafts are balanced separately. Deposits and
contamination on the compressor and turbine
wheels can lead to imbalance during operation.
Unless a new rotor assembly is installed,
the entire rotor assembly must be balanced
during each repair.

Balancing rotor assembly

1. Clean all parts of the rotor assembly (rotors,
bearing flange, seal bushing (oil deflector ring),
bush, compressor wheel and shaft nut) prior
to balancing.
2. The position of the parts relative to each other
must be marked.

Note: The rotor assembly must only be balanced

in planes A and B!

3. Support rotor assembly at bearing points (arrowed)

in balancing device.
4. Impermissible residual imbalance of the rotor
assembly must be reduced by taking off material
(see following paragraphs) in planes A and B to
the max. values stated in the table.

Turbocharger type Balancing plane A (C) in mmg Balancing plane B (T) in mmg

K36 4.0 3.1

K37 4.6 3.6

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Task Descriptions 441

Removing material at compressor wheel

1. During material removal in the area of the blade
base a minimum distance (X) of 2 mm must
be adhered to.
2. Any recesses must not show edges to the
surrounding area.

Removing material at turbine wheel

1. Material removal during balancing in a circle
segment of max. 150°.
2. Any recesses must not show edges to the
surrounding area.

Max. permissible material removal

Turbocharger Compressor Tu rbi n e

type

D R F G H
(mm) (mm) (mm) (mm) (mm)

K36 4 4 2.5 4.0 1.5

K37 4 5 2.5 4.0 1.5

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442 Task Descriptions

3.8.6 Exhaust turbocharger – Tolerances

Permissible contour gap for K36

Gap clearance between min. (mm) max. (mm)

A Compressor wheel contour 0.35 0.8

B Compressor wheel back – –

C Turbine wheel contour 0.62 1.06

D Turbine wheel back 0.8 1.2

– Axial play 0.08 0.135

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