Dodge ram truck 3500 1996 Service Manual page 1218

11 - 1 6 EXHAUST SYSTEM AND INTAKE MANIFOLD
B R
REMOVAL AND INSTALLATION (Continued)
charge air cooler (intercooler) outlet duct clamps to 8
N-m (74 in. lbs.) torque.
(9) Install and bleed the high pressure fuel lines.
Tighten the high pressure fuel line nuts to 2 4 N-m
(18 ft. lbs.) torque.
TURBOCHAiiEi DIESEL
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Disconnect the air intake pipe and exhaust
pipe (Fig. 3 6 ) .
Fig, 36 Air intake Pipe, Exhaust Pipe and
Turbocharger
(3) Remove the oil drain tube bolts.
(4) Remove the oil supply line.
(5) Disconnect the charge air cooler (intercooler)
inlet duct from the turbocharger (Fig. 37).
(6) Remove the turbocharger mounting nuts and
the turbocharger.
(7) I f the turbocharger is not to be installed imme­
diately, cover the opening to prevent material from
entering into the manifold.
(8) Clean and inspect the sealing surface.
CAUTION: The turbocharger is a precision piece of
equipment and should only be repaired by an
authorized facility. Disassembly is not recom­
mended, a s engine/turbo failure could result.
INSTALLATION
(1) Install a new gasket and apply anti-seize com­
pound to the mounting studs.
Fig, 37 Air Cooler (Intercooler) inlet Duct
(2) Install the turbocharger. Tighten the turbo­
charger mounting nuts to 32 N-m (24 ft. lbs.) torque.
(3) Use a new gasket and connect the drain line.
Tighten the drain line connection bolts to 24 N-m (18
ft. lbs.) torque.
(4) New turbocharger must be pre-lubricated with
clean engine lubricating oil before start up. Pour
50-60 cc (2-3 ounces) of oil into supply fitting.
WARNING: DO NOT U S E YOUR FINGER TO TURN
THE TURBINE WHEEL.
(5) Rotate the turbine wheel to allow oil to enter
the turbocharger.
(6) Install the oil supply line. Tighten the oil sup­
ply line fitting nut to 15 N-m (11 ft. lbs.) torque.
(7) Position the Charge air cooler (intercooler) inlet
duct to the turbocharger. With the clamp in position,
tighten the clamp nut to 8 N-m (72 in. lbs.) torque.
(8) Position the air intake pipe and the exhaust
pipe onto the turbocharger. Tighten the clamps to 8
N-m (72 in. lbs.) torque.
(9) Connect the negative cable to the battery.
(10) Operate the engine and check for leaks.
WASTEGATE ADJUSTMENT
The wastegate turbocharger provides additional
low speed boost without over-boost at high speeds.
This increases low speed torque and better driveabil-
ity.
Proper adjustment of the wastegate assembly is
critical to the operation of the wastegate turbo­
charger (Fig. 38). The control rod is set at the factory