SERVICE MANUAL is   delivered   to   the   combustion   chamber,      a   greater amount  of  fuel  is  required  to  obtain  the  correct  air-fuel mixture.      This   increased   consumption   of   fuel   at   the correct air-fuel ratio results in increased power output. Fig. 5.  Air and Exhaust Flow In Turbocharged Engine 1.  Air Intake 2.  Turbocharger 3.  Exhaust SERVICE PRECAUTIONS Regardless of their rugged appearance, turbochargers are to be handled with extreme care.  The internal  parts  are  manufactured  to  close  tolerances  and are  very  sensitive   to   accumulations   of   dirt,   nicks   and scratches. Care     must     be     taken     to     prevent     damage     to     the components while they are on the workbench. The   turbine   wheel,   compressor   impeller,   shaft and   related   parts   form   a   balanced   assembly   which rotates at very high speeds. Bending  of  the  turbine  or  compressor  vanes  or  removal of   any   vane   material   during   servicing   could   cause   a serious    out-of-balance    condition    which    could    quickly destroy the turbocharger. The greater air flow requirements of a turbocharged  engine  makes  it  extremely  important  that the  air  intake  system  be  kept  clean.    The  air  cleaner must    be  serviced  at  recommended  intervals  to  avoid power  loss  due  to  air  cleaner  restriction  and  to  prevent possible entry of dirt into the turbocharger and engine. Turbocharging  an  engine  is  more  than  merely bolting   on   the   turbocharger   and   driving   away.      The installation  must  be  carefully  engineered  to  provide  the best  performance  and  avoid  "overcharging"  which  could be  destructive.    Also,  the  engine  must  be  designed  to handle  the  greater  air  and  fuel  flow,  higher  pressures and   temperatures,   and   increased   torque   and   power output. After assembly, all openings in the turbocharger should    be    capped    or    taped    closed,    or    the    entire turbocharger should be encased in a clean polyethylene bag to prevent entry of foreign material.  Keep openings covered until the unit is installed on the engine. To     prevent     damage     to     the     bearings,     the turbocharger must be prelubricated at installation or if the engine has not been operated for a long period of  time. To   prelubricate   the   bearings,   place   4   to   5   ounces   of clean oil into the turbocharger oil inlet opening. GENERAL MAINTENANCE AND CLEANING PROCEDURES 1. Prevent    the    entrance    of    foreign    material    by covering    or    plugging    all    openings    into    the turbocharger  when  handling  or  assembling  the unit.      Covers   must   remain   in   place   until   the turbocharger is installed and all connections are secured. 2. All  connections  to  the  turbocharger   (manifolds and  piping)  must  be  clean  and  free  of  foreign material, since serious damage to the turbocharger or engine could result. All connections must be airtight. 3. Exhaust  stacks  of  extra  long  length  and  other fixtures    must    not    be    rigidly    attached    to    the turbocharger. 4. For initial running when installing a new or rebuilt turbocharger   or   after   the   engine   has   been   in storage  for  30  days  or  more  or  when  engine  oil filters  have  been  changed,  it  is  recommended that 4 to 5 ounces of oil (same type and grade as used  in  the  crankcase)  be  put  into  the  oil  inlet opening  in  the  turbocharger  with  a  squirt  can. This   will   provide   sufficient   lubrication   for   the turbocharger bearings until normal engine CTS-4104 Printed in United States of America Page 5