Content .. 485 486 487 488 ..

Chrysler RG Voyager. Manual - part 487

TURBOCHARGER

(

COOL DOWN

(

CHART

Driving

Load

Turbo-

charger

Idle Time (in

minutes)

Condition

Tempera-

ture

Before Shut

Down

Stop & Go

Empty

Cool

Less than 1

Stop & Go

Medium

Warm

Highway

Speeds

Medium

Warm

City Traffic

Max.

GCWR

Warm

Highway

Speeds

Max.

GCWR

Warm

Uphill

Grade

Max.

GCWR

Hot

REMOVAL

(1) Remove the battery and tray assembly (Refer

to 8 - ELECTRICAL/BATTERY SYSTEM/TRAY -
REMOVAL).

(2) Disconnect the mass air flow (MAF) sensor and

the intake air temperature (IAT) sensor wiring har-
ness connectors.

(3) Disconnect the air inlet tube at the breather

and remove the air cleaner cover.

(4) Raise and support the vehicle.
(5) Remove the exhaust system.
(6) Remove the lower engine splash shield.

(7) Loosen the turbocharger support bracket and

set aside.

(8) Remove the turbocharger flange (Fig. 6)
(9) Remove the auxiliary heater pipe fasteners and

position pipe aside.

(10) Disconnect the turbocharger oil supply and

return lines at the turbocharger.

(11) Remove the turbocharger to exhaust manifold

fasteners (Fig. 6).

(12) Disconnect the turbocharger wastegate actua-

tor vacuum line and remove the turbocharger (Fig.
6).

Fig. 5 Turbocharger Oil Supply and Drain

1 - BEARINGS
2 - OIL SUPPLY (FROM ENGINE BLOCK)
3 - OIL RETURN (TO OIL PAN)

Fig. 6 EXHAUST MANIFOLD AND TURBOCHARGER

1 - TURBOCHARGER OIL SUPPLY BANJO BOLT
2 - COPPER WASHER
3 - EXHAUST MANIFOLD GASKET
4 - COPPER WASHER
5 - EXHAUST MANIFOLD HEAT SHIELD RETAINING BOLT
6 - TURBOCHARGER
7 - ENGINE LIFT HOOK
8 - ENGINE LIFT HOOK RETAINING BOLT
9 - SPACER
10 - EXHAUST MANIFOLD RETAINING NUT
11 - TURBOCHARGER OIL RETURN HOSE
12 - HOSE CLAMPS
13 - EXHAUST MANIFOLD STUDS

11a - 4

EXHAUST SYSTEM

TURBOCHARGER (Continued)

CLEANING

All old gaskets should be inspected for any tears or

signs of prior leakage. If any gaskets show such indi-
cations, they should be replaced with new gaskets.
All gasket mating surfaces must be cleaned of old
gasket material to produce a smooth and dirt free
sealing surface for the new gasket.

INSPECTION

Visually inspect the turbocharger and exhaust

manifold gasket surfaces. Replace stripped or eroded
mounting studs.

(1) Visually inspect the turbocharger for cracks.

The following cracks are NOT acceptable:

• Cracks in the turbine and compressor housing

that go completely through.

• Cracks in the mounting flange that are longer

than 15 mm (0.6 in.).

• Cracks in the mounting flange that intersect

bolt through-holes.

• Two (2) Cracks in the mounting flange that are

closer than 6.4 mm (0.25 in.) together.

(2) Visually inspect the impeller and compressor

wheel fins for nicks, cracks, or chips. Note: Some
impellers may have a factory placed paint mark
which, after normal operation, appears to be a crack.
Remove this mark with a suitable solvent to verify
that it is not a crack.

(3) Visually inspect the turbocharger compressor

housing for an impeller rubbing condition (Fig. 7).
Replace the turbocharger if the condition exists.

(4) Measure the turbocharger axial end play:

(a) Install a dial indicator as shown in (Fig. 8).

Zero the indicator at one end of travel.

(b) Move the impeller shaft fore and aft and

record the measurement. Allowable end play is
0.038 mm (0.0015 in.) MIN. and 0.089 mm (0.0035
in.) MAX. If the recorded measurement falls out-
side these parameters, replace the turbocharger
assembly.
(5) Measure the turbocharger bearing radial clear-

ance:

(a) Insert a narrow blade or wire style feeler

gauge between the compressor wheel and the hous-
ing (Fig. 9).

(b) Gently push the compresser wheel toward

the housing and record the clearance.

gently push the compressor wheel away from the
housing and again record the clearance.

(d) Subtract the smaller clearance from the

larger clearance. This is the radial bearing clear-
ance.

(e) Allowable radial bearing clearance is 0.326

mm (0.0128 in.) MIN. and 0.496 mm (0.0195 in.)
MAX. If the recorded measurement falls outside
these specifications, replace the turbocharger assy.

Fig. 7 Inspect Compressor Housing for Impeller

Rubbing Condition - Typical

Fig. 8 Measure Turbocharger Axial End Play -

Typical

EXHAUST SYSTEM

11a - 5

TURBOCHARGER (Continued)

INSTALLATION

(1) Clean all gasket mating surfaces taking care

not to damage the sealing surfaces.

(2) Install the turbocharger to the exhaust mani-

fold (Fig. 6). Tighten fasteners to 32.4 N·m (24 lbs.
ft.).

(3) Connect the wastegate actuator vacuum line.
(4) Connect the turbocharger oil supply and return

lines (Fig. 6). Tighten supply bolt to 24.5 N·m (217
lbs. in.) and return fasteners to 10 N·m (89 lbs. in.)..

(5) Reposition and secure the auxiliary heater

pipes to floor board. Tighten bolts to 10.8 N·m (96
lbs. in.).

(6) Install the turbocharger flange (Fig. 6). Tighten

fasteners to 32.4 N·m (24 lbs. ft.).

(7) Secure

the

turbocharger

support

bracket.

Tighten fasteners to 47.1 N·m (35 lbs. ft.).

(8) Connect

the

exhaust

system.

Tighten

the

exhaust manifold to front pipe fasteners to 32 N·m
(24 lbs. ft.) and the exhaust support bracket fasten-
ers to 27.5 N·m (21 lbs. ft.).

(9) Install the lower engine splash shield.
(10) Lower the vehicle.
(11) Connect the air inlet hose to the breather and

install the air cleaner cover.

(12) Connect the MAF and IAT sensor harness

connectors.

(13) Install the battery and tray assembly (Refer

to 8 - ELECTRICAL/BATTERY SYSTEM/TRAY -
INSTALLATION).

(14) Start engine and inspect for leaks.

HEAT SHIELDS

REMOVAL

(1) Remove front wiper unit (Refer to 8 - ELEC-

TRICAL/WIPERS/WASHERS/WIPER

MODULE

REMOVAL).

(2) Remove engine cover (Refer to 9 - ENGINE -

REMOVAL).

(3) Partially drain cooling system (Refer to 7 -

COOLING/ENGINE/COOLANT - STANDARD PRO-
CEDURE).

(4) Remove thermostat housing to upper radiator

hose tube (Fig. 10).

(5) Remove exhaust manifold heat shield retaining

bolts and remove shield (Fig. 11).

Fig. 9 Measure Turbocharger Bearing Radial

Clearance - Typical

1 - FEELER GAUGE

Fig. 10 TURBOCHARGER AND COOLANT PIPES

1 - TURBOCHARGER OUTLET PIPE RETAINING BOLT
2 - TURBOCHARGER OUTLET PIPE
3 - ADAPTER HOSE
4 - HEAT SHIELD
5 - HOSE CLAMPS
6 - TURBOCHARGER INLET PIPE RETAINING BOLT
7 - TURBOCHARGER INLET PIPE
8 - ADAPTER HOSE
9 - HOSE CLAMPS
10 - EGR VALVE TO INTAKE AIR INLET PIPE
11 - CLAMP
12 - THERMOSTAT HOUSING TO UPPER RADIATOR HOSE PIPE

11a - 6

EXHAUST SYSTEM

TURBOCHARGER (Continued)

INSTALLATION

(1) Reposition exhaust heat shield (Fig. 11).
(2) Install exhaust heat shield retaining bolts (Fig.

11). Torque bolts to 27.5N·m.

(3) Install thermostat housing to upper radiator

hose tube (Fig. 10).

(4) Refill cooling system (Refer to 7 - COOLING/

ENGINE/COOLANT - STANDARD PROCEDURE).

(5) Install engine cover (Refer to 9 - ENGINE -

INSTALLATION).

(6) Install front wiper unit (Refer to 8 - ELECTRI-

CAL/WIPERS/WASHERS/WIPER

MODULE

INSTALLATION).

(7) Start the engine and inspect for exhaust leaks.

Repair exhaust leaks as necessary.

(8) Check the exhaust system for contact with the

body panels. Make the necessary adjustments, if
needed.

Fig. 11 EXHAUST MANIFOLD AND

TURBOCHARGER

EXHAUST SYSTEM

11a - 7

HEAT SHIELDS (Continued)

Content .. 485 486 487 488 ..