Turbocharger - Component Part Replacement Procedure
84chrysler5Models
1984 Conquest Equipped With 2.6L Turbocharged Engine
Subject
Turbocharger Component Part Replacement Procedure
Index
FUEL
Date
October 22, 1984
No.
14-41-84
P-4617-C
The turbocharger for subject model vehicles is now serviced by component parts as described in the parts list below.
In addition, the removal and installation procedure for servicing the turbocharger by component part is outlined in this bulletin.
PARTS REOUIRED
Conquest Turbocharger Component Part List (Figure 1)
1. Compressor Cover PN MD613544
2. O-Ring PN MD613776
3.. Turbine Cartridge Assembly PN MD613502
4. Snap Ring PN MD613591
*5. Coupling Band PN MD613590
6. Exhaust Turbine Housing PN MD613514
*7. Waste Gate Actuator Assembly PN MD613581
*8. Manifold Pressure Hose PN MD613594
*Can be replaced without removing turbo from engine.
PROCEDURE FOR COMPONENT SERVICE DISASSEMBLY
NOTE: REFER TO THE 1984 CONQUEST SERVICE MANUAL, PUBLICATION #81-270-4005, PAGES 14-18 THRU 14- 20 FOR TURBOCHARGER ASSEMBLY REMOVAL AND INSTALLATION PROCEDURE FROM THE ENGINE.
1. Remove the air intake hose, oil supply and oil return pipes, exhaust outlet mounting bolts to catalytic converter, and turbocharger to engine exhaust manifold mounting nuts. Remove turbocharger assembly from engine.
FIGURE 1:
2. Loosen the waste gate actuator mounting bolts, remove manifold vacuum hose, and remove the waste gate actuator from the compressor cover (Figure 1).
FIGURE 2:
3. Loosen the coupling band nut and remove the band and exhaust turbine housing and waste gate valve assembly (Figure 2).
CAUTION: NEVER ATTEMPT TO FIELD ADJUST THE WASTE GATE VALVE OR ACTUATOR, IT HAS BEEN ADJUSTED BY THE TURBOCHARGER MANUFACTURER.
FIGURE 3:
4. With the compressor cover facing down, remove the snap ring retaining the compressor cover using snap ring pliers (Figure 3).
CAUTION: WHEN REMOVING THE SNAP RING HOLD IT IN OPPOSITE THE PLIERS TO PREVENT IT JUMPING OUT OF THE GROOVE SUDDENLY (FIGURE 3).
FIGURE 4:
5. Tap the compressor cover all around with a soft faced hammer (plastic or rubber) to separate the turbine cartridge from the compressor housing (Figure 4).
NOTE: THE TURBINE CARTRIDGE ASSEMBLY MAY BE SOMEWHAT DIFFICULT TO SEPARATE FROM THE COMPRESSOR HOUSING BECAUSE OF THE O-RING INSTALLED ON THE OUTER EDGE OF THE CARTRIDGE.
ASSEMBLY
1. Remove any carbon or fuel residue stains from the inner surfaces of the exhaust turbine and compressor housing with carburetor cleaner and a brush. Blow dry and wipe off with a clean cloth.
FIGURE 5:
2. Install the turbine cartridge assembly to the exhaust turbine housing and install the coupling band loosely (Figure 5).
CAUTION: BE CAREFUL NOT TO DAMAGE THE TURBINE BLADES DURING HANDLING AND ASSEMBLY OF THE TURBINE CARTRIDGE.
3. Apply a thin coat of clean engine oil to the inside surface of the O-ring before it is installed to the cartridge assembly (Figure 5).
CAUTION: WHEN THE O-RING IS INSTALLED USE CARE NOT TO DAMAGE IT. A DAMAGED O-RING WILL LEAD TO OIL LEAKAGE.
FIGURE 6:
4. Apply a thin coat of clean engine oil to the outer surface of the O-ring installed on the cartridge assembly. Install the compressor cover using firm pressure to seat it over the O-ring (Figure 6).
5. With the compressor cover inverted, install the snap ring.
6. Before installing the turbocharger on the engine, approximately position the locations of the exhaust turbine housing, turbine cartridge assembly (to locate the oil return pipe), and the compressor outlet for easy installation on the engine.
7. Install the waste gate actuator assembly to the compressor, but do not fully tighten the mounting bolts. Install the manifold pressure hose between the compressor housing and waste gate actuator diaphragm.
8. Install the loosely assembled turbocharger assembly on the engine. Adjust the location of the exhaust turbine housing, turbine cartridge assembly, and compressor cover for proper alignment of catalytic converter, oil supply and return line, and other related parts.
9. Before installing the oil supply pipe be sure the oil return hose is permanently installed to turbine cartridge assembly. Next, pour 1/2 pint of clean engine oil in the oil supply pipe fitting to lubricate the turbine shaft bearings, thus preventing a dry start-up bearing failure. Permanently install the oil supply pipe.
10. Tighten the waste gate actuator bolts and torque the coupling band nut to 86.7 inch pounds to 95.6 inch pounds.
11. Start engine and allow to fully warm up at idle. Check for oil, air, and exhaust leaks. Repair as necessary.
POLICY: Reimbursable within the provisions of the warranty
TIME ALLOWANCE:
Labor Operation No. 09-44-05-01 - Wastegate Actuator-Replace 0.2 Hrs.
09-44-25-01 - Coupling Band-Replace 0.2 Hrs.
09-44-30-01 - Manifold Pressure Hose-Replace 0.2 Hrs.
09-45-20-01 - Turbocharger-Remove & Install 0.9 Hrs.
09-45-20-50 - Turbocharger-Replace 0.1 Hrs.
09-45-25-50 - Compressor Cover-Replace 0.3 Hrs.
09-45-30-50 - O-Rings-Replace 0.3 Hrs.
09-45-35-50 - Turbine Cartridge Assembly-Replace 0.4 Hrs.
09-45-40-50 - Snap Rings - Replace 0.3 Hrs.
09-45-45-50 - Exhaust Turbine Housing-Replace 0.2 Hrs.
FAILURE CODE: 2X - Vibration or Chatter
07 - Binds, Sticks or Seized
11 - Broken or Cracked
54 - Improperly Assembled
68 - Noisy