Jeep 2002 WJ Service Manual page 112

WG
EXHAUST SYSTEM AND TURBOCHARGER - 2.7L DIESEL
EXHAUST SYSTEM AND TURBOCHARGER -
2.7L DIESEL
DESCRIPTION - 2.7L DIESEL
DIAGNOSIS AND TESTING - DIESEL ENGINE
TURBOCHARGER SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REMOVAL - TURBOCHARGER
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
WASTEGATE
REMOVAL - WASTE GATE SOLENOID
EXHAUST SYSTEM AND
TURBOCHARGER - 2.7L
DIESEL
DESCRIPTION - 2.7L DIESEL
CAUTION: Avoid application of rust prevention com-
pounds or undercoating materials to exhaust sys-
tem floor pan exhaust heat shields. Light overspray
near the edges is permitted. Application of coating
will result in excessive floor pan temperatures and
objectionable fumes.
DIAGNOSIS AND TESTING - DIESEL ENGINE
CONDITION
EXCESSIVE EXHAUST NOISE OR
LEAKING EXHAUST GASES
EXHAUST SYSTEM AND TURBOCHARGER - 2.7L DIESEL
TABLE OF CONTENTS
page
. . . . . . . . . . . . . . . 1
. . 1
. . . . . . . . . . . . . . 2
. . . . . . . . 3
EXHAUST SYSTEM DIAGNOSIS CHART
POSSIBLE CAUSE
1. Leaks at pipe joints.
2. Rusted or expanded muffler.
3. Broken or rusted exhaust pipe.
4. Exhaust pipe leaking at manifold
flange.
5. Exhaust manifold cracked or
broken.
6. Leak between exhaust manifold
and cylinder head.
7. Turbocharger mounting flange
cracked.
8. Restriction in exhaust system.
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CHARGE AIR COOLER AND PLUMBING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING - CHARGE AIR
COOLER SYSTEM - LEAKS . . . . . . . . . . . . . . . 4
REMOVAL - CHARGE AIR COOLER
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION - CHARGE AIR COOLER
The diesel engine exhaust system consists of an
engine exhaust manifold, turbocharger, exhaust pipe,
resonator, extension pipe (if needed), muffler and
exhaust tailpipe.
The exhaust system must be properly aligned and
secured to prevent stress, leakage and body contact.
The exhaust components should be kept a minimum
of 25.4 mm (1.0 in.) away from the body and frame.
If the system contacts any body panel, it may amplify
objectionable noises from the engine or body.
1. Tighten/replace clamps/bolts at
leaking joints.
2. Replace muffler. Inspect exhaust
system.
3. Replace exhaust pipe.
4. Tighten/replace flange attaching
nuts/bolts.
5. Replace exhaust manifold.
6. Tighten/replace exhaust manifold
to cylinder head bolts.
7. Remove turbocharger and
inspect.
8. Remove restriction, if possible.
Replace restricted part if necessary.
11a - 1
page
. . . . . . . . . . 4
. . . . . . 5
CORRECTION