Chapter 4 Part B_ Turbocharger Contents ‘See Chapter 1 Air fiter cleaning and replacement ‘Air cleaner assembly — removal and installation ‘See Chapter 4, Part A Intake and exhaust manifold — removal ‘and installation ‘See Chapter 2 ‘Turbocharger — checking a Engine idle speed check and adjustment. ‘See Chapter 1. Turbocharger — removal and installation 2 Exhaust system check See Chapter 1 Throttle linkage check. ‘See Chapter 1 General information 1 ‘Specifications ‘Torque specifications Nm Felbs Exhaust pipe-to-transmission mount brace Exhaust pipe clamp nuts 7 5 Brace-to-transmission nuts 20 15 ‘Turbocharger flange-to-exhaust pipe nut 20 t0 26 1510 18 ee 1. General information ——eee— ‘The turbocharger system increases power by using an exhaust gas turbine located between the exhaust manifold end the exhaust pi 'ssurize the fuel/air mixture as it enters the combustion chambe ‘rom the engine is used for turbocharger lubrication and cooling, The system incorporates a boost pressure control valve which vents 2 Turbocharger — removal and installation 1 Disconnect the negative battery cable. 2 Remove the air cleaner and bracket assembly (Chapter 4, Part A, Fig. 48.1 Turbocharger component layout (Sec 1) Compressor housing Compressor whee! Genter housing Bearings Shaft Turbine housing Turbine whee! Boost pressure control valve Connecting hose Compressor intake (fresh ait) Compressor discharge fcompressed air) Exhaust gases to the bypass duct Exhaust gases to the turbine wheel Exhaust gas dischargeFig. 48.2 Turbocharger system operation (Sec 1) Compressor wheel Turbine whee! Boost pressure control valve Connecting hose Exhaust manifold Boost air pipe Overload protection capsule Pressure line Boost pressure switch air pipe Valve overload protection Exhaust gas to bypass duct ey [compressor int rot a HEBEEE compressor outlet (pre-compressed air) Fig. 48.3 Turbocharger system ‘component layout (See 2) Intake hose Hose clip Air intake rubber sealing ring Turbocharger Outer rubber sealing ring Adapter fitting Inner rubber sealing Flange gasket Heat-resistant nut Washer Intake manifold Pressure switch Sealing ring Delivery line trom intake ‘manifold Union screw Hose clip Connecting hose ‘Switchover valve Aneroid compensator delivery line Nut Washer Gasket Aneroid compensator Exhaust gases to turbine wheel Exhaust gas outlet126 Chapter 4 Part B Turbocharger 2.3. The turbocharger oil line is held in place by two bolts ‘ ows) 2.7. The flexible coupling is held in place by two straps with bolts (arrows). Also shown is one of the two flange collar bolts (arrow, upper left of photo) 2.9. Grasp the turbocharger firmly and lift it away from the ‘manifold while holding the oll line out of the way ~~ f the exhaust pipe retaining nuts (arrows) is made 19 oil is applied to the threads 2.6 Removal ‘easier if penet 2.8 The turbocharger-to-exhaust manifold nuts (arrows) are located in a tight space but they can be removed with an open ‘end wrench Section 8) and remove the turbocharger air intake hose. 3. Disconnect the turbocharger oil pie at the turbocharger (photo) 4 Remove the turbocharger heat shield 5 Apply penetrant oll tothe threads of all of the turbocharger attach- Ing nuts and bolts prior to removal 6 Remove the exhaust pipe flange nuts and pry the pipe away from the studs (photo) 7. Remove the two bolts retaining the flexible coupling straps and then completely remove the retaining straps. Remove the two flange Collar bolts, twist the flange collar for clearance and then pull it free {rom the flexible coupling. The flexible coupling can then be worked free of the turbo unit (photo) 8 Remove the four turbocharger retaining nuts (photo). 9 Disengage the turbocharger and oll return pipe and lft the assembly from Ithe engine (photo. 10. Remove the trubocharger-to-intake manifold fitting, noting the direction in which it is installed 41. Remove the flange gasket from the exhaust manifold and clean the contact surfaces of the manifold and turbocharger.Chapter 4 Part B_ Turbocharger Fig. 48.4 Turbocharger oil return pipe component layout (Sec 2) 60 Upper oil pan 93 O-ring 90 Gasket 94 Lower oil return pipe 91 Bolts 95 Seal 92 Upper oil return pipe 12 Install a new flange gasket on the exhaust manifold, withthe raised bead side against the manifold 18 Install manifold fitting, place the turbocherger in postion and in- stall the retaining nuts. New O-rings should be used on the turbocharger-to-intake manifold fiting. Tighten the nuts securely. 44 Install the flexible coupling and connect the exhaust pipe. Tighten i nuts and bolts securely. 127 165 Install the he: 16 Ha new tutboch pint (1/8 liter) of clean engi 7. Place the cil pipe and new gasket in position and install the bolts. Tighten the bolts securely. 18 Install the air cleaner 19 Connect the battery cable, .embly. rt the engine and check for leaks. ‘3 Turbocharger — checking ively simple design, the turbocharger is a precision 1 While a compare uPPIY device which can be severely damaged by an interrupted oF ‘of loose or damaged ducting. 2. Due to the special techniques and equipment required, any hecking ‘diagnosis of suspected problems should be left to your dealer. The home mechanic can, however, check the connections and linkages for security, damage or obvious faults. 3. Because each turbocharger has its own distinctive sound, a change in the noise level can be a sign of potential problem: 4 Ahigh-pitched or whistling sound is a symptom of an inlet air or exhaust gas leak. Another sign of a loose duct or an exhaust leak is, ow engine power. Check the ait ducting between the air cleaner and the turbocharger connection to the exhaust manifold for loose con- nections or leaks. 5 White exhaust smoke and/or oll in the intake or exhaust is cation of a faulty internal seal within the turbocharger. 6 fan unusual sound issues from the vicinity ofthe turbine, the duct. ing can be removed and the turbine wheel inspected. Warning: Ai! checks must be made with the engine off and coo! to the touch and the turbocharger stopped or personal injury could result. Operating the turbocharger without all the ducts and fters installed is also dangerous {and can result in damage to the turbine wheel blades. 7” Check the operation of the turbine wheel to make sure itturns fre ly. Hfitdoes not, this could be a sign that the cooling oil he (oF coked from overheating. Push inward on the shaft wheels for binding. The wheel should rotate freely with no binding or rubbing fon the housing 8 Inspect the exhaust manifold for cracks and loose connections. 9 Because the turbine wheel rotates at speeds up to 140,000 rpm, ‘severe damage can result from the interruption or contamination of the oil supply to the turbine bearings. Check for leaks in the oll return pipe for obstructions, as this can cause severe oilloss through the turbo- ‘charger seals. Burned oll on the turbine housing is a sign of this. Note: “Any time @ major engine bearing such as @ main, connecting rod or ‘camshaft bearing is replaced, the turbocharger should be flushed with clean oil in indli-