Jeep XJ. Manual — part 330
CAUTION: Heatshield is very sharp. Wear gloves to
prevent injury.
(19) Remove the exhaust downpipe heatshield by
pulling straight up.
(20) Remove the (5) bolts attaching the exhaust
downpipe to the turbocharger and remove pipe.
(21) Remove the (8) exhaust manifold retaining
bolts, it is necessary to access the bolt behind the
manifold outlet from the underneath of the vehicle.
(22) Remove the exhaust manifold and turbo-
charger assembly from the vehicle
(23) Place assembly in a vice to remove the (3)
exhaust manifold to turbocharger retaining nuts (Fig.
8).
Cleaning
Always use new gaskets during assembly. All gas-
ket mating surfaces must be cleaned of old gasket
material to produce a smooth and dirt free sealing
surface for the new gasket.
INSTALLATION
(1) Transfer the oil return line to the new turbo-
charger (Fig. 8).
(2) Install the turbo on the exhaust manifold (Fig.
8). Torque the nuts to 32 N·m (23 ft. lbs.).
(3) Install the exhaust manifold and turbocharger
assembly in the vehicle
(4) Install the (8) exhaust manifold retaining nuts.
Torque nuts to 32 N·m (23 ft. lbs.).
(5) Install the exhaust manifold downpipe. Torque
bolts to 32 N·m (23 ft. lbs.).
CAUTION: Heatshield is very sharp. Wear gloves to
prevent injury.
(6) Slide the exhaust downpipe heatshield down
over pipe. Do not attempt to strap heatshield in posi-
tion at this time, wait until vehicle is raised on hoist.
(7) Install the oil supply line on turbocharger.
Torque bango bolt fitting to 27 N·m (20 ft. lbs.).
(8) Connect the heater hoses.
(9) Position and install the exhaust manifold heat-
shield. Torque bolts to 11 N·m (97 in. lbs.).
(10) Raise the vehicle on a hoist.
(11) Connect the turbocharger oil return line to the
engine block (Fig. 9).
(12) Strap the exhaust downpipe heatshield in its
original position.
(13) Install the exhaust system support clamp
(Fig. 10). Torque nuts to 23 N·m (17 ft. lbs.).
Fig. 7 Turbocharger Oil Return Hose
1 – VEHICLE UNDERBODY
2 – RIGHT ENGINE MOUNT THROUGHBOLT NUT
3 – TURBOCHARGER OIL RETURN HOSE
4 – EXHAUST MANIFOLD DOWNPIPE
5 – TURBOCHARGER
Fig. 8 Turbocharger / Exhaust Manifold Assembly
1 – OIL RETURN LINE
2 – WASTEGATE VACUUM SUPPLY HOSE
3 – TURBO TO EXHAUST MANIFOLD RETAINING NUTS
4 – BENCH VISE
5 – TURBOCHARGER ASSEMBLY (REMOVED FROM VEHICLE)
6 – WASTEGATE VACUUM ACTUATOR
11 - 4
EXHAUST SYSTEM AND TURBOCHARGER
XJ
REMOVAL AND INSTALLATION (Continued)
2000 JEEP CHEROKEE
(14) Connect the exhaust system at the (3) bolt
flange (Fig. 10). Torque the bolts to 23 N·m (17 ft.
lbs.).
(15) Lower the vehicle from the hoist.
(16) Install the intake manifold elbow and EGR
valve as an assembly. Torque bolts to 27 N·m (20 ft.
lbs.).
(17) Install the (2) bolts holding the EGR tube to
the EGR valve. Torque bolts to 27 N·m (20 ft. lbs.).
(18) Install the innercooler inlet and outlet hoses
on the engine (Fig. 11).
(19) Install the EGR vacuum supply hose on the
EGR valve.
(20) Install the air filter cover and outlet hose on
turbocharger (Fig. 11).
(21) Connect the breather hose on the air cleaner
outlet hose (Fig. 11).
(22) Fill the cooling system. Refer to Group 7,
Cooling System for procedure.
(23) Connect the negative battery cable
(24) Start the engine and check for leaks.
EXHAUST MANIFOLD AND TURBOCHARGER
(RHD)
REMOVAL
(1) Disconnect the negative battery cable
(2) Disconnect the breather hose from the air
cleaner outlet hose.
Fig. 9 Turbocharger Oil Return Hose
1 – VEHICLE UNDERBODY
2 – RIGHT ENGINE MOUNT THROUGHBOLT NUT
3 – TURBOCHARGER OIL RETURN HOSE
4 – EXHAUST MANIFOLD DOWNPIPE
5 – TURBOCHARGER
Fig. 10 Exhaust System Inlet Pipe Connection
1 – EXHAUST INLET PIPE RETAINING BOLTS
2 – EXHAUST SYSTEM SUPPORT CLAMP
Fig. 11 Engine Compartment
1 – INTAKE MANIFOLD ELBOW
2 – BREATHER HOSE
3 – INNERCOOLER OUTLET HOSE
4 – AIR FILTER COVER
5 – AIR FILTER OUTLET (FRESH AIR) HOSE
6 – INNERCOOLER INLET HOSE
7 – HEATER CORE COOLANT SUPPLY HOSES
XJ
EXHAUST SYSTEM AND TURBOCHARGER
11 - 5
REMOVAL AND INSTALLATION (Continued)
2000 JEEP CHEROKEE
(3) Remove the air filter cover and the hose from
the turbocharger, remove the assembly.
(4) Raise the vehicle on a hoist.
(5) Drain the cooling system. Refer to Group 7,
Cooling System for the procedure.
(6) Remove the exhaust system support clamp
(Fig. 12).
(7) Disconnect the exhaust system at the (3) bolt
flange (Fig. 12).
CAUTION: Heatshield is very sharp. Wear gloves to
prevent injury.
(8) Unstrap the exhaust downpipe heatshield (Fig.
13).
CAUTION: Heatshield is very sharp. Wear gloves to
prevent injury.
(9) Remove the exhaust downpipe heatshield by
pulling straight down.
(10) Disconnect the turbocharger oil return hose
from the engine block (Fig. 14).
(11) Lower the vehicle from the hoist.
(12) Disconnect the heater supply and return
hoses from the right side of the engine. Remove the
steel line support bracket from the top of the rocker
cover and position the assembly out of the way
(13) Remove the EGR vacuum supply hose from
the EGR valve.
(14) Remove the innercooler inlet and outlet hoses
from the engine.
(15) Remove the (2) bolts holding the EGR tube to
the EGR valve.
Fig. 12 Exhaust System Inlet Pipe Connection
1 – EXHAUST INLET PIPE RETAINING BOLTS
2 – EXHAUST SYSTEM SUPPORT CLAMP
Fig. 13 Exhaust Downpipe Heatshield
1 – EXHAUST MANIFOLD DOWNPIPE HEATSHIELD RETAINING
STRAPS
Fig. 14 Turbocharger Oil Return Hose
1 – VEHICLE UNDERBODY
2 – RIGHT ENGINE MOUNT THROUGHBOLT NUT
3 – TURBOCHARGER OIL RETURN HOSE
4 – EXHAUST MANIFOLD DOWNPIPE
5 – TURBOCHARGER
11 - 6
EXHAUST SYSTEM AND TURBOCHARGER
XJ
REMOVAL AND INSTALLATION (Continued)
2000 JEEP CHEROKEE
(16) Remove the intake manifold elbow and the
EGR valve as an assembly.
(17) Remove the EGR tube from the exhaust man-
ifold.
(18) Remove the (2) exhaust manifold heatshield
retaining bolts and remove the heatshield (Fig. 15).
(19) Remove the oil pressure supply line from the
turbocharger (Fig. 15).
(20) Remove the clutch master cylinder heatshield
(Fig. 15).
(21) Remove the turbocharger oil supply line from
the engine block (Fig. 16).
(22) Working inside of the vehicle, remove the
Knee Blocker. Refer to Group 8E, Instrument Panel
Systems for the procedure.
(23) Disconnect the neutral safety switch electrical
connector at the clutch pedal.
(24) Remove the (2) clutch master cylinder retain-
ing nuts from the bulkhead.
(25) Working from the inside of the engine com-
partment, remove the clutch master cylinder from
the bulkhead and position the cylinder and line
assembly out of the way.
(26) Remove the (5) bolts attaching the exhaust
downpipe to the turbocharger and remove the pipe.
(27) Remove the (8) exhaust manifold retaining
bolts, it is necessary to access the bolt behind the
manifold outlet from the underneath of the vehicle.
(28) Remove the steering shaft pinchbolt and slide
the shaft straight off of the gearbox input shaft. Posi-
tion aside.
(29) Remove the exhaust manifold and the turbo-
charger assembly from the vehicle
(30) Place the turbo assembly in a vice to remove
the (3) exhaust manifold to turbocharger retaining
nuts (Fig. 17).
Cleaning
Always use new gaskets during assembly. All gas-
ket mating surfaces must be cleaned of all old gasket
material to produce a smooth and dirt free sealing
surface for the new gasket.
INSTALLATION
(1) Install the turbocharger on the exhaust mani-
fold (Fig. 17). Torque nuts to 32 N·m (23 ft. lbs.).
(2) Install the exhaust manifold and turbocharger
assembly in the vehicle
(3) Install the (8) exhaust manifold retaining nuts,
it is necessary to access the bolt behind the manifold
outlet from underneath the vehicle. Torque nuts to 32
N·m (23 ft. lbs.).
(4) Install the exhaust manifold downpipe. Torque
the bolts to 32 N·m (23 ft. lbs.).
Fig. 15 2.5L Turbo Diesel — Heatshields
1 – CLUTCH MASTER CYLINDER HEATSHIELD
2 – TURBO OIL PRESSURE SUPPLY LINE
3 – TURBOCHARGER
4 – EXHAUST MANIFOLD HEATSHIELD RETAINING BOLTS
Fig. 16 R. H. D. Turbo Position & Orientation
1 – CLUTCH MASTER CYLINDER
2 – EXHAUST DOWNPIPE HEATSHIELD
3 – TURBOCHARGER OIL PRESSURE SUPPLY LINE AT TURBO
4 – TURBOCHARGER OIL PRESSURE SUPPLY LINE AT ENGINE
BLOCK
5 – ACTUATOR VACUUM SUPPLY
6 – TURBOCHARGER WASTEGATE ACTUATOR
XJ
EXHAUST SYSTEM AND TURBOCHARGER
11 - 7
REMOVAL AND INSTALLATION (Continued)
2000 JEEP CHEROKEE
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст