Turbocharger - Diesel Ford Cab & Chassis Ranger

COMPONENT TESTING

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

APPLICATION

ENGINE CODE

DESCRIPTION

A turbocharger is used on Ford 2.3L diesel engines to improve fuel efficiency and performance. Turbocharger assembly is mounted on right side of engine, and consists of a turbine/compressor assembly, oil supply system and wastegate.

OPERATION

As air/fuel mixture is burned, greater volume of hot exhaust gas enters exhaust system. This gas is directed into turbine housing of turbocharger. Energy contained in exhaust gas is used to increase speed of turbine wheel, which drives compressor wheel. Compressor wheel forces incoming air through plenum chamber and into intake manifold.

The amount of boost is controlled by a wastegate and diaphragm. As boost increases, diaphragm pushes against wastegate actuator rod, opening wastegate. Exhaust gases are then diverted away from turbine.

TURBINE ASSEMBLY

Turbocharger is mounted on right side of engine. Turbine and compressor are connected by a shaft. Hot exhaust gases are fed into turbine through exhaust manifold. Gases hitting turbine blades cause blades to spin, which in turn, causes compressor wheel to spin.

WASTEGATE & PRESSURE REGULATOR

A wastegate controls amount of boost allowed into engine. Exhaust gas enters turbine continuously. Once engine demand is satisfied and proper boost level is attained, wastegate, acting on command from pressure regulator, by-passes enough exhaust gas into exhaust system to maintain required turbine speed.

The pressure regulator is a pressure-sensitive diaphragm unit. It is installed so it can sense pressure differential between intake manifold and compressor. Once this differential reaches a certain level, diaphragm reacts on an integral spring, to partially open wastegate.

OIL SUPPLY

Rotating assembly, consisting of turbine wheel, connecting shaft and compressor wheel, can reach speeds in excess of 50,000 RPM. Engine oil enters turbocharger housing through an inlet fitting, and returns to oil pan through an oil return line. A steady supply of clean engine oil is absolutely necessary for proper operation. Any interruption or contamination of oil may result in major turbocharger damage.

Any time center housing rotating assembly is replaced (in part or in whole), oil and filter should be changed. If oiling system has been contaminated, oil and filter must be changed, and assembly must be flushed with clean oil.

PRESSURE RELIEF VALVE

A pressure relief valve, located on intake manifold, diverts excess boost into the atmosphere. This valve will open if wastegate cannot divert enough exhaust gas away from turbine wheel, or if a malfunction occurs, preventing proper operation of wastegate system.

Pressure relief valve opens when boost pressure exceeds a predetermined amount. On Ford vehicles, "CHECK ENGINE" light will come on while valve is open. The lamp will go out when boost drops (and valve closes).

TESTING

Note. Turbochargers are serviced by replacement ONLY.

BEARING AXIAL CLEARANCE CHECK

1. Attach a dial indicator with tip of indicator against end of shaft. Manually move shaft in one direction as far as possible and zero dial indicator.
2. Move shaft in extreme opposite direction (without rotating shaft) and observe dial indicator.
3. Rotate shaft 90° and check bearing clearance again. If bearing axial clearance is greater than .0012-.0031" (.03-.08 mm), replace turbocharger assembly.

TURBOCHARGER ASSEMBLY

Before servicing turbocharging system, ensure the following precautions have been taken

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 cause turbocharger failure when engine is started.
3. Scribe reference marks on turbine and compressor housing before disassembly to ensure correct reassembly position.
4. If any joints are found to be coated with sealer, clean thoroughly and recoat with sealant during assembly.

Removal

1. Remove 2 bolts connecting exhaust pipe to turbocharger. Disconnect air cleaner assembly. Remove oil supply line bolts at top of turbocharger center housing. Remove clamp from oil lines and remove oil return line.
2. Remove bolt and sealing washers (if equipped) connecting oil supply line to oil filter housing. Remove bolts connecting turbocharger to exhaust manifold.

Installation

1. Clean mating surfaces of turbocharger and exhaust manifold. Using new seals (if equipped) on oil supply line, reverse removal procedure to install. Disconnect fuel cut-off solenoid at injection pump and disconnect glow plug harness from engine wiring harness.
2. Crank engine several times (30 seconds maximum), until oil pressure light goes out. Reconnect fuel cut-off solenoid and glow plug harness, and start engine. Check for exhaust leaks.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS