Diesel Engine Turbocharger Removal?

The Procedure for Dodge Sprinter Van/ Truck models.

The details covers Dodge Diesel Engine models 2.7L and 3.0L models.


The procedure with help diagrams is as follows.


Turbocharger
REMOVAL & INSTALLATION:

2.7L Engine

1. Disconnect the negative battery cable.
2. Remove the heat shield.
3. Separate the front exhaust pipe from the turbocharger.
4. Separate the charge air and intake air hoses at the turbocharger.
5. Disconnect the servomotor electrical connector at servomotor.
6. Disconnect the oil supply line.
7. Remove the turbocharger support bracket.
8. Remove the turbocharger from exhaust manifold.
9. Remove the oil return line from turbocharger.

To install:

1. Clean all of the mating surfaces.
2. Install the oil return tube and gasket onto the turbocharger. Tighten the bolts to 80 inch lbs. (8 Nm).
3. Insert the oil return tube into block and install the turbocharger to the exhaust manifold. Tighten the mounting bolts to 15 ft. lbs. (20 Nm).
4. Install the turbocharger support bracket and tighten the bolts to 15 ft. lbs. (20 Nm) at the engine and 22 ft. lbs. (30 Nm) at the turbocharger.
   
   NOTE

   Counterhold the connection at the turbocharger when tightening the oil supply line bolt.
5. Replace the gaskets and install oil supply line at the turbocharger. Tighten the bolt to 13 ft. lbs. (18 Nm).
6. Connect the servomotor electrical connector.
7. Attach the air intake and charge air hoses.
8. Connect the front exhaust pipe to the turbocharger. Tighten flange clamp to 22 ft. lbs. (30 Nm).
9. Install the heat shield.
10. Connect the negative battery cable.

3.0L Engine

1. Disconnect the negative battery cable.
2. Drain the cooling system.
3. Remove the engine appearance cover.
4. Remove the air cleaner to turbo intake tube.
5. Remove the engine cover front bracket.
6. Remove the turbo to cooler air turbo.
7. Remove the turbo heat shield.
8. Remove the elbow-to-converter exhaust clamp.
9. Remove the turbo front bracket retaining bolts.
10. Raise and safely support the vehicle.
11. Remove the front splash shield.
12. Disconnect the downstream catalytic converter at the extension pipe.
13. Disconnect the extension pipe to muffler.
14. Disconnect the O2 sensor wire connector.
15. Reposition the extension pipe and catalytic converter.
16. Lower the vehicle
17. Disconnect catalytic converter to downstream catalytic converter clamp.
18. Remove upstream catalytic converter.
19. Disconnect the transmission fill tube and trim cover bracket and set aside.
20. Disconnect exhaust elbow at turbo.
21. Disconnect EGR tube at manifold to left cylinder head.
22. Remove left and right exhaust manifold retaining bolts and gaskets. 
    
    
    Fig. Remove the exhaust clamp (1), exhaust elbow (2), EGR tube (3) and manifold retaining bolts (4) to access the turbo-3.0L Engine
23. Remove the front turbo retaining bolts.
24. Remove the turbo mount retaining bolts.
25. Remove the turbocharger assembly.
26. Disconnect the turbo boost pressure servo connector. 
    
    
    
    Fig. Remove the front turbo bolts (1) and turbo mount retaining bolts to remove the turbocharger-3.0L engine

To install:

1. Reconnect the turbo boost pressure servo connector, if it was disconnected.
2. Position and install the turbocharger on the exhaust manifold, tighten the mount retaining bolts to 22 ft. lbs. (30 Nm).
3. Install the front turbo retaining bolts and gasket.
   
   CAUTION

   Make sure the gasket is installed properly or the turbo oil feed hole will be blocked.
4. Install left and right exhaust manifold retaining bolts and gaskets (4).
5. Reconnect EGR tube at manifold to left cylinder head (3).
6. Reconnect EGR tube at manifold to left cylinder head (3).
7. Reconnect the transmission fill tube and trim cover bracket.
8. Install the upstream catalytic converter.
9. Raise and safely support the vehicle.
10. Reconnect catalytic converter to downstream catalytic converter clamp.
11. Install the extension pipe and catalytic converter.
12. Reconnect the O2 sensor wire connector.
13. Reconnect the extension pipe to muffler.
14. Reconnect the downstream catalytic converter at the extension pipe.
15. Install the front splash shield.
16. Lower the vehicle.
17. Install the turbo front bracket retaining bolts.
18. Install the exhaust clamp (elbow to converter)
19. Install the turbo heat shield.
20. Install air tube (turbo to cooler).
21. Install the engine cover front bracket.
22. Install the air intake tube (air cleaner to turbo)
23. Install the engine appearance cover.
24. Connect the negative battery cable.

These details will help.

Thanks.           

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html