Chrysler RAM TRUCK 2500 1994 Service Manual page 911

11 - 22 EXHAUST SYSTEM AND INTAKE MANIFOLD
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(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 Y O U R FINGER TO TURN
T H E TURBINE W H E E L .
(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 i n 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. 34). The control rod is set at the factory
and no adjustment should be necessary, unless
wastegate assembly is damaged.
CAUTION: DO NOT adjust the wastegate s o that
higher pressures are required to open the waste-
gate valve. The turbocharger speed will be in­
creased and can c a u s e damage to the turbocharger
and c a u s e a loss of engine performance.
(1) Connect regulated air pressure to the waste-
gate actuator (Fig. 35). 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 ac­
tuator. 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.
(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. 36). Pull the wastegate lever toward the
actuator (closed position).
Fig. 34 Wastegate Turbocharger
Fig. 35 Wastegate and Dial Indicator
(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. 36).
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. 36).
(6) Recheck the travel on the wastegate control
rod. Adjust, i f necessary.
CHARGE AIR COOLER (INTERCOOLER)
Intake air is drawn through the air cleaner and
into the turbocharger compressor housing. Pressur-