Just in case I have not previously posted this to the forum. Basic instructions on aligning the turbos. It is for those who can learn on their own.

Do not send me questions as I am too busy lately, and will not respond.

 

Thought I would save you all the time.


TURBO CARTRIDGES:

(1) For each turbo cartridge, make matching punch marks on the cartridge and turbo housing so that they can be aligned at that point where the cartridge goes into the turbo housing.

(2) For each turbo cartridge, on the back side of the compressor housing, where the retaining "C" clip does not cover the surface where the aluminum housing meets the steel turbo plate, I ground a matching slot in the aluminum to a small dimple on the steel
plate. On the aluminum housing with a Magic Marker, I pointed to it and wrote (for the rebuilder to see), "Here is the alignment mark". Also mention this to them in a letter.

(3) When you get them back, make sure that (2) marks are aligned or at least 1/16" within alignment. If not, the "C" clip has to be compressed and the housings rotated until aligned. This takes two people. Insert the cartridges into the housing, align the two punch marks, and bolt them up.

TURBO HOUSING:

(4) Turbo housing alignment does not use any marks. This is only needed if it is taken apart for WG enlargement. Best to do it on the exhaust manifold. Loosely assemble the housing and bolt it to the exhaust manifold. Hand tighten the housing nuts. This aligns the mating surfaces of the housing to the surface of the exhaust manifold. Remove the housing and finish tightening the assembly nuts. The alternate way requires using a straight edge across the housing mating surfaces to insure that both sides are in the same plane. Then tighten the nuts.


IF THESE STEPS WERE NOT TAKEN OR IF THE COMPLETE TURBO ASSEMBLY IS BADLY MIS-ALIGNED, THEN YOU HAVE TO DO THIS:


Do (4) first.

Loosely attached both turbos to the housing so they can be rotated. Only attach the oil inlet line to them but only hand tighten. The exhaust manifold has to be already on the motor. Place assembly on the manifold and hand tighten with a few nuts. Rotate the turbos together until the oil inlet line connectors match up properly. Hand tighten them together. Tighten at lease one of the 6 bolts for each cartridge so they will not rotate. Take turbo assemble off, tighten all 12 turbo attaching bolts, then properly torque the oil inlet line to both turbo cartridges.

Place it all back on the engine again. Only attach the front half of the "Y" pipe to the #1 turbo. Try attaching the connecting pipe between the "Y" pipe and IC. If the #1 turbo outlet is too far off alignment, then you have to adjust it to make the IC pipe fit properly. If misaligned, try to judge by how much off it is. Remove the assembly from the exhaust manifold, loosen the #1 turbo compressor housing "C" clip and rotate the compressor housing by your prior noted judgment amount. Repeat the process until the "Y" pipe to IC pipe alignment is correct. The "Y" pipe also has to clear the air pump pipes.

Remove the assembly again. Now install, and check how the rear half of the
"Y" pipe aligns with the front half. If it doesn't or is a tight fit, then you have to loosen the #2 turbo "C" clip and rotate it's compressor housing until the "Y" pipe
aligns correctly.

Now you can attach the oil return lines, water lines, and heat shield.