Dodge RAM TRUCK 1500 1995 Service Manual page 1051

1 1 - 2 0 EXHAUST SYSTEM AND INTAKE MANIFOLD
(0.013 - 0.050 in) total travel. If the rod travel is out
of limits, the wastegate linkage must be adjusted.
(3) To adjust the wastegate linkage, apply air pres­
sure to the actuator to release the spring tension on
the lever. Remove the control rod from the wastegate
lever (Fig. 3). Pull the wastegate lever toward the ac­
tuator (closed position).
(4) Adjust the length of the clevis end of the con­
trol rod to align the clevis pin hole to the wastegate
lever. Install the adjusting link and retaining clip
(Fig. 3).
CAUTION; DO NOT pull, push or force the align­
ment of the clevis pin.
(5) After the adjustment is complete, tighten the
actuator rod jam nut (Fig. 3).
WASTEGATE ACTUATOR J9411 -17
Fig. 3 Adjustment of Wastegate Actuator
(6) Recheck the travel on the wastegate control
rod. Adjust, if necessary.
CHARGE AIR COOLER—INTERCOOLER
Intake air is drawn through the air cleaner and
into the turbocharger compressor housing. Pressur­
ized air from the turbocharger then flows forward
through the charge air cooler (intercooler) located in
front of the radiator. From the charge air cooler (In­
tercooler) the air flows back into the intake manifold.
The charge air cooler (Intercooler) is a heat ex­
changer that uses air flow to dissipate heat from the
intake air. As the turbocharger increases air pres­
sure, the air temperature increases. Lowering the in­
take air temperature increases engine efficiency and
power.
REMOVAL
WARNING: IF THE ENGINE W A S J U S T TURNED
OFF, THE INTAKE AND OUTLET DUCTS MAY B E
HOT
(1) Remove the grille (refer to Group 23, Body for
the proper procedure).
(2) Remove the front support bracket (Fig. 4).
(3) If the vehicle is equipped with air conditioning,
remove the condenser as follows:
(a) Discharge the air conditioning system (refer
to Group 24, Heating and Air Conditioning for the
proper procedures).
(b) Remove the bolt from the sealing plate (Fig.
4).
(c) Remove the nuts holding the condenser to the
charge air cooler (intercooler) (Fig. 4). Lift the con­
denser and sealing plate assembly away from the
charge air cooler (intercooler).
Fig. 4 Condenser and Charge Air Cooler—
Intercooler
(4) Remove the inlet and outlet ducts from the
charge air cooler (intercooler)—(Fig. 5).
(5) Remove the charge air cooler (intercooler) bolts.
Pivot the charge air cooler (intercooler) forward and
up to remove.
CLEANING
If the engine experiences a turbocharger failure or
any other occasion where oil or debris is put into the
charge air cooler, the charge air cooler must be
cleaned.
(1) Remove the charge air cooler from the vehicle,
refer Charge Air Cooler in this section.
(2) Flush the charge air cooler internally with a
non caustic solvent in the opposite direction of nor­
mal air flow. Shake the charge air cooler and
LIGHTLY tap on the end tanks with a rubber mallet
to dislodge trapped debris. Continue flushing until
all debris or oil is removed.
(3) Use a flashlight and mirror to visually inspect
the charge air cooler for internal debris.
CAUTION: If internal debris cannot be removed,
scrap the charge air cooler.