Dodge ram truck 3500 1996 Service Manual page 1221

BR EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 19
CLEANING
A N D
INSPECTION
( C o n t i n u e d )
INTERCOOLER—CHARGE AIR COOLER
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
L I G H T L Y
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. DO NOT USE CAUSTIC
CLEANERS TO CLEAN THE CHARGE AIR COOLER.
DAMAGE TO THE CHARGE AIR COOLER WILL
RESULT.
(4) After the charge air cooler has been thoroughly
cleaned of all oil and debris with the non caustic sol­
vent, wash the charge air cooler internally with hot
soapy water to remove the remaining solvent.
(5) Rinse thoroughly with clean water.
(6) Blow compressed air into the charge air cooler
in the opposite direction of normal air flow until the
charge air cooler is dry internally.
INSPECTION
(1) Visually inspect the charge air cooler
(2) Inspect the tubes, fins and welds for tears,
breaks or other damage. I f any damage causes the
charge air cooler to fail, the charge air cooler must
replaced.
CATALYTIC CONVERTOR
INSPECTION
Look at the stainless steel body of the catalytic,
inspect for bulging or other distortion that could be a
result of overheating. I f the catalytic has a heat
shield attached make sure i t is not bent or loose.
WARNING: UNLEADED FUEL MUST BE USED TO
PREVENT BLOCKAGE OR CONTAMINATION TO
THE CATALYST CORE.
I f you suspect internal damage to the catalyst, tap­
ping the bottom of the catalyst with a rubber mallet
may indicate a damaged core.
CLEANING
Clean ends of pipes and muffler to assure a good
seal at mating surfaces.
A D J U S T M E N T S
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. 43). The control rod is set at the factory
and no adjustment should be necessary, unless
wastegate assembly is damaged.
Fig. 43 Wastegate Turbocharger
CAUTION: DO NOT adjust the wastegate so that
higher pressures are required to open the waste-
gate valve. The turbocharger speed will be
increased and can cause damage to the turbo­
charger and cause a loss of engine performance.
(1) Connect regulated air pressure to the waste-
gate actuator (Fig. 44). Install a dial indicator to
measure the control rod movement. Apply 103 - 138
kPa (15 - 20 psi) to seat the components and take
any slack out of the control rod. Release the air pres­
sure and zero the dial indicator gauge.
(2) Apply 133 kPa (19.3 psi) air pressure to the
actuator. The control rod should move 0.33 - 1.27 mm
(0.013 - 0.050 in) total travel. I f the rod travel is out
of limits, the wastegate linkage must be adjusted.