Dodge Ram Truck 1500-2500-3500. Manual — part 1435
The turbocharger is lubricated by engine oil that is
pressurized, cooled, and filtered. The oil is delivered to
the turbocharger by a supply line that is tapped into
the oil filter head. The oil travels into the bearing hous-
ing, where it lubricates the shaft and bearings. A
return pipe at the bottom of the bearing housing,
routes the engine oil back to the crankcase.
The most common turbocharger failure is bearing fail-
ure related to repeated hot shutdowns with inadequate
“cool-down” periods. A sudden engine shut down after
prolonged operation will result in the transfer of heat
from the turbine section of the turbocharger to the
bearing housing. This causes the oil to overheat and
break down, which causes bearing and shaft damage
the next time the vehicle is started.
Letting the engine idle after extended operation allows
the turbine housing to cool to normal operating tem-
perature. The following chart should be used as a
guide in determining the amount of engine idle time required to sufficiently cool down the turbocharger before shut
down, depending upon the type of driving and the amount of cargo.
TURBOCHARGER “COOL DOWN” CHART
Driving Condition
Load
Turbocharger
Temperature
Idle Time (in minutes) Before
Shut Down
Stop & Go
Empty
Cool
Less than 1
Stop & Go
Medium
Warm
1
Highway Speeds
Medium
Warm
2
City Traffic
Max. GCWR
Warm
3
Highway Speeds
Max. GCWR
Warm
4
Uphill Grade
Max. GCWR
Hot
5
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EXHAUST SYSTEM
DR/DH
REMOVAL
TURBOCHARGER
1. Disconnect the battery negative cables.
2. Raise vehicle on hoist.
3. Disconnect the exhaust pipe from the turbocharger
elbow (Refer to 11 - EXHAUST SYSTEM/EX-
HAUST PIPE - REMOVAL).
4. Remove the bolts from the turbocharger oil drain
tube.
5. Disconnect wastegate command valve connector.
6. Remove two lower turbocharger mounting nuts.
7. Lower vehicle.
8. Disconnect the turbocharger air inlet hose.
9. Disconnect the turbocharger oil supply line from the
turbocharger.
10. Disconnect the charge air cooler inlet pipe from
the turbocharger compressor outlet.
11. Remove two upper turbocharger mounting nuts.
12. Remove the turbocharger and gasket from the
exhaust manifold.
13. If the turbocharger is not to be installed immedi-
ately, cover the opening to prevent material from
entering into the manifold.
14. If replacing the turbocharger, transfer the turbo-
charger oil supply fitting to the new assembly.
Tighten fitting to 36 N·m (27 ft. lbs.).
15. Clean and inspect the sealing surface.
CAUTION: The Wastegate Command Valve, and
Command Valve O-ringd are the only serviceable
components
on
the
turbocharger.
The
turbo-
charger itself is serviced as a component. Do not
attempt to repair the turbocharger as turbocharger
and/or engine damage can result.
DR/DH
EXHAUST SYSTEM
11 - 27
TURBOCHARGER OIL DRAIN TUBE
1. Disconnect negative battery cables.
2. Raise vehicle on hoist.
3. Remove two turbocharger oil tube mounting bolts
4. Pulling upward, remove the turbocharger drain tube
from the engine block.
CLEANING
WARNING: To prevent damage or personal injury, do not use a combustible cleaner to clean the turbo-
charger.
Clean the turbocharger, turbocharger oil drain tube flange, and exhaust manifold mounting surfaces with a suitable
scraper.
INSPECTION
Visually inspect the turbocharger and exhaust manifold
gasket surfaces. Replace stripped or eroded mounting
studs.
1. Visually inspect the turbocharger for cracks. The
following cracks are NOT acceptable:
•
Cracks in the turbine and compressor housing
that go completely through.
•
Cracks in the mounting flange that are longer
than 15 mm (0.6 in.).
•
Cracks in the mounting flange that intersect bolt
through-holes.
•
Two (2) Cracks in the mounting flange that are
closer than 6.4 mm (0.25 in.) together.
2. Visually inspect the impeller and compressor wheel
fins for nicks, cracks, or chips. Note: Some impel-
lers may have a factory placed paint mark which, after normal operation, appears to be a crack. Remove this
mark with a suitable solvent to verify that it is not a crack.
3. Visually inspect the turbocharger compressor housing for an impeller rubbing condition. Replace the turbocharger
if the condition exists.
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EXHAUST SYSTEM
DR/DH
4. Measure the turbocharger axial end play:
a. Install a dial indicator as shown in. Zero the
indicator at one end of travel.
b. Move the impeller shaft fore and aft and record
the measurement. Allowable end play is 0.026
mm (0.0001 in.) MIN. and 0.127 mm (0.005 in.)
MAX. If the recorded measurement falls out-
side these parameters, replace the turbo-
charger assembly.
5. Measure the turbocharger bearing radial clearance:
a. Insert a narrow blade or wire style feeler gauge
between the compressor wheel and the hous-
ing.
b. Gently push the compressor wheel toward the
housing and record the clearance.
c. With the feeler gauge in the same location,
gently push the compressor wheel away from
the housing and again record the clearance.
d. Subtract the smaller clearance from the larger
clearance. This is the radial bearing clearance.
e. Allowable radial bearing clearance is 0.33 mm
(0.013 in.) MIN. and 0.50 mm (0.020 in.) MAX. If the recorded measurement falls outside these specifica-
tions, replace the turbocharger assembly.
DR/DH
EXHAUST SYSTEM
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