Turbocharger Dodge Daytona I

APPLICATION

CHRYSLER MOTORS

DESCRIPTION

The turbocharging system is mounted on the manifold 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 causing compressor wheel to draw in air.

Maximum manifold pressure (boost) is controlled by the exhaust wastegate. Operation of the wastegate is controlled by a solenoid and the Single Module Engine Controller (SMEC).

COMPRESSOR

Air is drawn into the compressor through an air inlet duct and the throttle body. Forced air from turbocharger enters into the intake manifold. Exhaust gas is directed into the turbocharger turbine housing where it is used to increase speed of the turbine.

Scheme 11

Scheme 12

TURBINE ASSEMBLY

The turbine is connected to the compressor by a shaft. The exhaust gas passes across the turbine wheel blades. This forces the turbine wheel to rotate. Increased exhaust gas volume and pressure causes an increase in turbine speed. Faster rotation of the turbine increases compressor output.

WASTEGATE & ACTUATOR

The wastegate limits intake manifold pressure to a pre-set maximum. The actuator is a pressure-sensitive diaphragm. Operation of the wastegate is controlled by a solenoid and the SMEC.

As maximum boost pressure is obtained, the actuator causes the wastegate to open. At this point, a portion of the exhaust gas is diverted around the turbine and enters the header pipe directly. The wastegate is mounted to the turbine assembly.

OIL SUPPLY

Turbochargers must have constant flow of clean engine for proper operation. Oil is supplied directly into the center housing of turbocharger. Oil feed pipe runs from fitting on the engine block to the turbocharger center housing. Excess engine oil is returned into the engine block by a tube attached to housing of turbocharger. Change oil, filter and flush turbocharger with clean oil ANYTIME there is oil contamination.

REMOVAL PRECAUTIONS

Prior to any unit repair 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 damage to 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 alignment during assembly.
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. Drain cooling system. Remove exhaust pipe from turbocharger housing. Disconnect oxygen sensor electrical connector. Remove turbocharger housing-to-block support bracket.
2. Loosen oil drain hose clamps. Slide hose downward on block fitting. Remove coolant tube nut and coolant tube bracket at block outlet (below the steering pump bracket).
3. Remove air cleaner assembly including throttle body adapter, hose, air cleaner box and bracket. Remove accelerator linkage. Remove throttle body wiring connector, and vacuum hoses.
4. Loosen throttle body inlet hose clamps. Remove throttle body attaching screws and throttle body. Loosen turbocharger discharge hose end clamps ONLY.
5. Fuel rail must be repositioned to gain access to turbocharger. Remove 4 intake manifold bracket screws and the 2 heat shield bracket retaining clips. Move fuel rail upward out of the way. Remove heat shield retaining screws from intake manifold. Remove heat shield.
6. Remove oil feed line from turbocharger. Remove coolant return tube from turbocharger. Remove return coolant tube assembly and tube support from cylinder head.
7. Remove turbocharger retaining nuts while holding turbocharger to exhaust manifold. Lift turbocharger from exhaust manifold studs. Push passenger side of unit downward, and lift turbocharger from engine compartment.

Installation

To install, reverse removal procedures. Ensure turbocharger tightening specifications are followed. Apply anti-seize compound to exhaust manifold studs. Ensure that turbine wheel turns freely before installing exhaust pipe.

Note. It may be necessary to remove intake and exhaust manifold to remove turbocharger.

1. Remove negative battery cable. Drain cooling system. Remove air cleaner assembly. Remove intake manifold support bracket from cylinder head. Separate throttle body assembly from intake manifold.
2. Disconnect EGR tube, PCV, MAP and brake booster vacuum hoses. Disconnect Charge Temperature Sensor electrical leads. Remove starter. Remove upper intake manifold retaining bolts. Separate upper and lower intake manifold components. DO NOT allow gasket material to fall into intake ports of engine.
3. Remove cowl mounted heat shield. Fuel rail pressure must be released before removing fuel rail. To release fuel pressure, remove fuel tank cap. Remove wiring harness from any injector. Ground one terminal of injector wiring harness.
4. Connect jumper wire to second terminal while touching to battery voltage for no longer than 10 seconds. This releases fuel pressure from fuel lines. Remove jumper wires. Remove inlet hose from fuel rail. Disconnect vacuum hose from fuel pressure regulator to intake manifold.
5. Remove fuel pressure regulator mounting bolts. Loosen fuel line clamp at fuel pressure regulator. Remove fuel pressure regulator. Remove fuel rail-to-valve cover bracket. Disconnect fuel injector wiring at main connector. Remove fuel injector heat shield clips.
6. Remove fuel rail-to-intake manifold bolts. Remove fuel rail and injectors as an assembly. Use care not to damage "O" rings on injectors during removal.
7. Disconnect oil feed line at oil sending unit. Disconnect return coolant tube from water box. Remove oil feed line and return coolant tube with support bracket. Remove the right intermediate shaft, bearing support bracket and outer drive shaft assemblies.
8. Remove the turbocharger-to-block support bracket. Disconnect exhaust pipe from turbocharger housing. Disconnect oxygen sensor electrical connection. Loosen oil drain hose clamps. Slide hose downward on block fitting. Remove pressure coolant tube nut and coolant tube bracket at the block outlet below the steering pump bracket.
9. Remove turbocharger retaining nuts while holding turbocharger to exhaust manifold. Carefully lift turbocharger from exhaust manifold studs.

To install, reverse removal procedures. Ensure turbocharger tightening specifications are followed. Apply anti-seize compound to exhaust manifold studs. Ensure that turbine wheel turns freely before installing exhaust pipe.

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 or wheel. If a high-pitched noise or whistle occurs, check for inlet air or exhaust gas leak.

Note. Chrysler Motors recommends complete replacement of turbocharger assembly if found defective. No overhaul procedures exist for this unit.

1. Remove exhaust outlet pipe from turbocharger housing. Using a mirror, observe movement of the wastegate while operating the actuator linkage manually.
2. If wastegate fails to open or close, replace turbocharger assembly. Spin the compressor wheel and check for binding. Replace turbocharger if binding exists. NOTE: If turbocharger is being replaced, change engine oil and filter.
3. Remove the oil drain back from the center housing. Check center housing for sludging in the oil drain area. If necessary, replace the engine oil. If heavily sludged or caked, replace turbocharger assembly. NOTE: Whenever oil and filter are changed, oil system must be primed. Disable ignition system. Crank engine several times (30 seconds maximum). Observe when oil light goes out. This enables lubrication to turbocharger before starting engine. Assemble ignition system.
4. Remove the throttle body and inspect compressor wheel and housing for signs of oil leakage, gouges, nicks, or distortion. If damaged or oil leakage, replace turbocharger assembly.

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

WASTEGATE ACTUATOR ASSEMBLY TESTING

1. Remove hose from wastegate actuator assembly. Connect cooling system pressure tester to wastegate diaphragm. Slowly apply pressure and note wastegate actuator rod operation.
2. Actuator rod should not move more than .015" (.38 mm) at 4 psi (.28 kg/cm 2 ). If actuator rod does not move at 5 psi (.35 kg/cm 2 ), 4 psi (.28 kg/cm 2 ) for Turbo II, wastegate is faulty. Turbocharger must be replaced if wastegate fails to operate at proper pressure.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS