Turbocharger - Gasoline Chrysler LeBaron II

COMPONENT TESTING

Note. Specific component testing information not available. Refer to any tests performed during REMOVAL & INSTALLATION or OVERHAUL procedures

APPLICATION

CHRYSLER CORP.

DESCRIPTION

The turbocharging system is mounted on the right side of the 2.2L engine. It includes a turbine assembly, center housing rotating assembly, compressor assembly, wastegate and throttle body. The turbine is spun by exhaust gas and causes compressor to draw air.

The throttle body is controlled by the ECM and various sensors, to provide the exact air/fuel mixture requirements. Maximum manifold pressure (boost) is controlled by an exhaust by-pass valve called a wastegate.

OPERATION

Air is drawn through an air inlet duct and throttle body, into the compressor, then forced into the intake manifold, where the fuel is injected. As engine load increases and throttle is opened, more air/fuel mixture flows into the combustion chambers. As this mixture is burned, a greater volume of hot exhaust gas enters exhaust system. This gas is directed into turbocharger turbine housing.

Some energy contained in exhaust gas is used to increase speed of turbine wheel. The turbine wheel is connected by a shaft to compressor wheel. As the compressor wheel spins faster, it compresses incoming air and forces a denser air/fuel mixture into the combustion chambers. Higher engine power output is the result.

2.2L Turbocharged Engine Components. Scheme 40

TURBINE ASSEMBLY

The turbine is connected to the compressor by a shaft. When the turbine wheel turns, the compressor wheel must turn. Hot exhaust gas is fed into the turbine through a tube. The exhaust gas hitting the turbine blades causes the blades to spin. The more exhaust gas entering the turbine, the faster it will spin, in turn spinning compressor faster. Thus, the turbocharger can produce more power as demand increases.

WASTEGATE & ACTUATOR

When manifold pressure (boost) reaches a predetermined level, there must be some method of controlling or limiting the boost past that point. The wastegate performs this function. Exhaust gas is piped into the turbine continuously. Once engine demand is satisfied and the proper boost level is attained, the wastegate, acting on command from the actuator assembly, by-passes enough exhaust gas into the exhaust system to maintain the required turbine speed.

The actuator is a pressure-sensitive diaphragm which responds to the boost pressure controlled by the ECM wastegate solenoid. Once the pressure differential across the compressor reaches a certain level, the diaphragm partially opens the wastegate. The wastegate is mounted to the turbine assembly.

COMPRESSOR

The compressor is connected directly to the turbine by a shaft, therefore, the speed of the turbine wheel will be the same as the compressor wheel. No exhaust gas is actually passed into the compressor. The spinning compressor forces more air into the intake manifold than would normally be drawn in under atmospheric pressure.

With a higher intake manifold pressure and denser charge available, more air/fuel mixture is drawn into the combustion chamber on the piston intake stroke. A denser mixture results in more power output from engine. The faster the compressor spins, more air is compressed into manifold.

OIL SUPPLY

The rotating assembly, consisting of turbine wheel, connecting shaft, and compressor wheel, can reach speeds of 140,000 RPM. A sufficient supply of clean engine oil is absolutely necessary for proper operation of assembly. Engine oil is fed directly to the center housing rotating assembly. An oil feed pipe runs from a fitting on the engine block to the turbocharger. Any interruption or contamination of the oil will result in major turbocharger damage.

Whenever the oiling system has been contaminated in any way, change the oil and filter, and flush the turbocharger assembly with clean oil. Any time the center housing rotating assembly is replaced, in part or in whole, the oil and filter should be changed.

TESTING

Note. Chrysler Corp. testing procedures are not available.

TURBOCHARGER ASSEMBLY

Before beginning any unit repair procedures on a turbocharging system, several general precautions should be considered.

1. Clean area around turbocharger with non-caustic solution before disassembly.
2. Use extreme care during removal to avoid damaging turbine blades. Any damage may result in turbocharger failure when engine is started.
3. Scribe reference marks on turbine and compressor housing before disassembly to ensure correct reassembly.
4. If any joints are found to be coated with sealer, clean thoroughly and recoat with sealant during assembly.

Removal

1. Disconnect negative battery cable and drain cooling system. Disconnect exhaust pipe at the turbocharger housing. Disconnect oxygen sensor electrical connector. Remove turbocharger housing-to-block support bracket.
2. Loosen oil drain hose clamps and move hose down on block nipple. Disconnect the coolant tube nut and coolant tube bracket at the block outlet (below the steering pump bracket).
3. Remove the air cleaner assembly including throttle body adapter, hose, air cleaner box and bracket. Disconnect the accelerator linkage, throttle body wiring connector, and vacuum hoses.
4. Loosen the throttle body inlet hose clamps. Remove the 3 throttle body attaching screws and the throttle body. Loosen the turbocharger discharge hose (end clamps ONLY).
5. Relocate the fuel rail by removing the 4 intake manifold bracket screws and the 2 heat shield bracket retaining clips. Move fuel rail up out of the way. Remove the 3 screws holding heat shield to intake manifold. Remove heat shield.
6. Remove the coolant return tube assembly from the turbocharger-to-water box. Remove the tube assembly and the tube support from cylinder head. Disconnect the oil feed line from turbocharger bearing housing.
7. Remove the 4 nuts holding the turbocharger-to-exhaust manifold. Lift the turbocharger off the exhaust manifold studs. Push passenger side of unit downward, and lift out of the engine compartment.

Installation

To install, reverse removal procedures noting the following: Ensure turbocharger tightening specifications are followed. Apply Loctite anti-seize compound to exhaust manifold studs.

Remove turbocharger from vehicle. Remove the wastegate-to-actuator rod clip. Remove vacuum hose. Remove retaining screws/bolts from actuator-to-turbocharger. Remove the actuator assembly.

To install, reverse removal procedure.

INTERNAL INSPECTION

Note. Each turbocharger has a unique noise level when operating. If the sound cycles up and down, check for air restrictions in the intake tube and for dirt build-up in the compressor housing/wheel. If a high-pitched noise or whistle occurs, look for an inlet air or exhaust gas leak.

Note. Chrysler Corp. recommends complete replacement of the turbocharger assembly if it is found defective. No overhaul procedures exist for this unit.

1. Remove the exhaust outlet pipe from turbocharger. Using a mirror, observe movement of the wastegate while operating the actuator linkage manually.
2. If wastegate fails to open or close, replace the assembly. Remove the turbocharger assembly from engine. DO NOT separate the center housing rotating assembly from the turbine housing.
3. Inspect for loose backplate-to-center housing rotating assembly bolts. Tighten if needed. Gently spin the compressor wheel. Replace if binding. NOTE: If turbocharger is being replaced, change engine oil and filter.
4. Remove the oil drain from the center housing. Check the housing for sludging in the oil drain area. If necessary, replace the engine oil. If heavily sludged or caked, replace the turbocharger assembly. NOTE: Whenever oil and filter are changed, oil system must be primed. Disconnect Dark Blue wire at distributor, crank engine several times (30 seconds maximum), observe when oil light goes out, reconnect Dark Blue wire, and start engine.
5. Remove the throttle body and inspect the compressor wheel/housing for signs of oil leakage, gouges, nicks, and/or distortion. If present, replace turbocharger assembly.

Note. Before connecting the exhaust pipe to the turbocharger assembly, gently spin the turbine wheel to be sure it is not binding or scraping housing.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS