Group 25 Intake and Exhaust System Service Procedures
3
W2000734
Fig. 37: Replacing intake manifold gasket
Adjust the alternator, A/C refrigerant
compressor, drive belt tension if so
equipped.
4
Install the pre-heater (if equipped) or
the spacer, using new gaskets, and
bolt the mounting to the fan shroud.
5
Install the boost air gauge connections
to the intake manifold.
6
Reconnect the terminals to the sen-
sors for the boost air pressure and the
boost air temperature on the intake
manifold. Tie the electrical cables.
2551-03-02-02
Turbocharger, Replacement
Before working on a vehicle, set the parking brakes,
place the transmission in neutral, and block the
wheels. Failure to do so can result in unexpected
vehicle movement and can cause serious personal in-
jury or death.
WARNING
HOT ENGINE! Keep yourself and your test equipment
clear of all moving parts or hot engine parts and/or
fluids. A hot engine and/or fluids can cause burns or
can permanently damage test equipment.
W2000943
Fig. 38: Turbocharger assembly
1 n/a
2 Exhaust pressure governor
3 Oil delivery and return pipes
4 Clamp
5 Nuts
General Guidelines and Precautions
Always determine the reasons for replacing a tur-
bocharger before making the repair. Correct any noted
defects before replacing.
When replacing a turbocharger, always thoroughly read
and carefully follow the procedures.
After degreasing, wipe the cooler clean and dry it with
compressed air. Also check the air pipes and charge air
hose. If contaminated with oil, replace the charge air
hose to prevent damage to the rubber.
The engine oil system and intake system must be kept in
good condition to ensure proper turbocharger operation.
That is, change oil and filters at specified times, use the
correct engine oil and properly care for the air cleaner.
When replacing a turbocharger, use compressed air to
remove any rust or carbon flakes from the exhaust mani-
fold. Carbon flakes can damage the turbine of the new
unit. It is also important to clean the intake pipe from the
air filter. Pieces of broken components can remain in the
pipe and cause immediate turbocharger failure.
Also, always check to be sure that the injection equip-
ment is in good condition.
Note: Once the turbocharger is installed put oil in oil
supply port to ensure proper turbo lubrication. Once
turbo is sufficently lubricated you can crank the engine.
Removal
1
Remove the air cleaner hose from the
turbocharger.
32
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