Turbocharger - Lack of Boost/Grinding Noises
85chrysler05
Models
1984 Conquest
Subject
Lack of Turbocharger Boost and/or Grinding Noise From the Turbo Assembly
Index
FUEL
Date
(current)
No.
14-23-85
SYMPTOM/CONDITION
Lack of turbocharger boost which results in poor engine performance and/or grinding noises from tubocharger assembly..
DIAGNOSIS
Follow the turbo diagnosis and inspection procedure that is described on page 14-19 of the 1984 Conquest Service Manual, publication #81- 270-4005. If it is determined the turbine cartridge bearings have failed, proceed with the installation of the water cooled turbocharger conversion kit outlined below.
PARTS REOUIRED
1 Turbo Cartridge, Water Cooled PN MD613504
1 Turbo Plumbing Kit PN MD997171
1 Turbo Cartridge "O" Ring PN MD613776
1 02 Sensor Gasket PN MD041864
1 Exhaust Manifold Gasket PN MD102683
1 Oil Pipe Joint PN MD017359
1 Oil Pipe Joint Gasket PN MF660064
NOTE: FOR COMPONENT PART SERVICE OF THE WATERCOOLED TURBO SYSTEM REFER TO THE 1985 CONQUEST PARTS CATALOG.
REPAIR PROCEDURE
1. Disconnect negative terminal of battery.
2. Drain engine coolant and oil. Remove air filter to turbocharger rubber air inlet duct and set it aside. Save coolant.
FIGURE 1 - Fuel Mixer Crossover Tube:
Remove turbo to fuel mixer crossover tube (Figure 1).
FIGURE 2 - Turbo Heat Shield:
FIGURE 3 - Oil Joint Fitting:
FIGURE 4 - Chain Case Cover:
3. Remove and discard turbo heat shield (Figure 2). Remove oxygen sensor from catalytic converter. Disconnect the oil supply pipe flair nut. Remove and discard the oil joint fitting from turbo (Figure 3). Disconnect turbo oil return hose from side of chain case cover (Figure 4).
FIGURE 4 - Chain Case Cover:
FIGURE 5 - Cylinder Head Nuts:
4. Remove the catalyst to turbo nuts, save heat shield bracket (Figure 4). Remove exhaust manifold heat shield (Figure 4). Remove the exhaust manifold to cylinder head nuts (Figure 5). Remove turbo and exhaust manifold from engine assembly and move to work bench. Remove turbo assembly from exhaust manifold.
FIGURE 6 - Exhaust Turbine Housing:
FIGURE 7 - Compressor Housing and Turbine Cartridge:
TURBO DISASSEMBLY
A. Remove waste gate actuator.
B. Remove the coupling band from exhaust to turbine housing. Remove exhaust turbine housing and inspect it for cracks or internal damage. Replace as required (Figure 6).
C. Index the compressor cover with a grease pencil using the oil supply hole as the reference point for the new turbine cartridge (Figure 6). With the compressor cover facing down, remove the snap ring retaining the compressor cover using snap ring pliers. Tap the compressor cover all around with a soft faced hammer (plastic or rubber) to separate the turbine cartridge from the compressor cover (Figure 7).
FIGURE 8 - Compressor Cover:
Inspect inside of compressor cover for cracks or damage due to contact with turbine blades. Replace as required (Figure 8).
TURBO ASSEMBLY
CAUTION: BE CAREFUL NOT TO DAMAGE THE TURBINE BLADES DURING HANDLING AND ASSEMBLY OF THE REPLACEMENT TURBINE CARTRIDGE.
A. Remove any carbon or fuel residue stains from the inner surfaces of the exhaust turbine and compressor cover with spray carburetor cleaner and a brush. Blow dry and wipe off with a clean cloth.
FIGURE 9 - Cartridge Assembly:
B. Apply a thin coat of clean engine oil to the surface of the O-ring installed on the cartridge assembly (Figure 9). Install the turbine assembly in the compressor cover, lining up the index mark from Step 3 to the oil supply hole on new turbine assembly. Use firm pressure to seat the O-ring in the compressor cover.
FIGURE 7 - Compressor Housing and Turbine Cartridge:
Install the compressor cover snap ring with the beveled side up (Figure 7).
C. Install the turbine cartridge assembly to the exhaust housing and install the coupling band loosely.
Remove the oil return line from original turbine cartridge and transfer it to the new turbine assembly. Use the new gasket supplied in kit and tighten bolts to 72 to 84 inch pounds torque.
Install the new oil pipe joint, PN MD173359, with gasket, PN MF660064, in turbine assembly. Tighten joint to 16 to 20 foot pounds torque.
Reinstall the waste gate actuator assembly to turbocharger.
D. Reinstall turbo assembly to exhaust manifold. Tighten nuts to 37 to 50 foot pounds torque and set aside for reinstallation on engine in a later step.
FIGURE 10 - Heater Pipe and Hose Assembly Location:
5. Remove the original metal heater pipe and hose from right side of engine (Figure 10). Remove the original oil supply pipe from oil filter adapter and discard. Install supplied heater pipe and hose assembly (Figure 10).
6. Reinstall exhaust manifold with turbo assembly to cylinder head using new exhaust manifold gasket, PN MD060907, and supplied nuts and washers.
Figure 11 - LOCATION OF OIL PIPE BRACKET "A" AND WATER PIPE BRACKET "B":
Secure oil feed pipe support bracket "A" to forward most nut on the exhaust manifold. A washer is not necessary on this nut (Figure 11). Tighten all manifold nuts to 11 to 14 foot pounds torque. Install exhaust manifold heat shield and water pipe bracket "B" (Figure 11).
FIGURE 1 - Fuel Mixer Crossover Tube:
Reinstall turbo to mixer crossover tube. At this time tighten the coupling band nut to 35 to 43 inch pounds torque (Figure 1).
Install supplied oil feed pipe to oil filter adaptor and turbine assembly. Tighten lower flair nut to 12 to 17 foot pounds torque, but do not tighten upper flair nut at this time.
Connect catalytic converter to exhaust housing using new gasket from kit. Tighten nuts to 37 to 50 foot pounds torque.
Reinstall the 02 sensor in catalyst housing using new gasket, PN MD041864.
FIGURE 1 - Fuel Mixer Crossover Tube:
Install supplied turbo heat shield (Figure 1).
FIGURE 12 - Thermostat Housing and Aspirator Control Module:
FIGURE 13 - LOCATION OF UPPER WATER PIPE BRACKET ON VALVE COVER:
7. Remove black aspirator control module from above thermostat housing and remove thermostat housing and discard (Figure 12).
Install supplied thermostat housing using new gasket. Tighten to 86 to 113 inch pounds torque. Reinstall aspirator control module.
8. Install longest water pipe to thermostat housing and secure to the driver side of turbo using banjo bolt and two washers. Tighten banjo bolt to 25 to 36 foot pounds torque.
FIGURE 2 - Turbo Heat Shield:
Install short water pipe to heater pipe assembly installed in Step 5. Secure to passenger side of turbo using banjo bolt and two washers. Tighten banjo bolt to 25 to 36 foot pounds torque. Install supplied turbo heat shield (Figure 2).
Reconnect the turbo oil return hose to chain case cover. Install the rubber air inlet duct from air cleaner to compressor cover.
9. Refill cooling system with coolant. Replace engine oil filter, PN MD031805. Refill crank case with Mopar Turbo Oil (SF/CD rating), PN 4318071 (1OW 30 quarts) which is highly recommended for all turbo engines.
FIGURE 14 - Turbo Bearings Lubrication:
Just prior to starting engine, pour approximately 1/2 pint of clean engine oil in the oil feed pipe fitting to lubricate the turbine shaft bearings to prevent a dry start-up bearing failure (Figure 14).
Fully tighten the upper flair nut fitting at this time. Tighten to 12 to 17 foot pounds torque.
10. Start engine and allow engine to idle until fully warmed up.
Check installation for coolant, air or vacuum, and exhaust leaks. Repair as required.
POLICY: Reimbursable within the provisions of the warranty
TIME ALLOWANCE: 09-45-20-90............................ 4.0 Hrs. Labor Operation No.
FAILURE CODE: 68 - Noisy