Fuel system DODGE RAM 1500 1998 2.G Repair Manual

(32) Disconnect fuel heater, water in fuel sensor,
and fuel lift pump connectors.
(33) Remove the fuel filter assembly-to-cylinder
head bolts and remove filter assembly from vehicle.
(34) Remove wire harness P-clip from cylinder
head (located behind filter housing).
(35) Remove the cylinder head cover(Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(36) Disconnect rocker housing injector harness
connectors.
(37) Remove injector harness nuts from injectors.
(38) Remove the rocker levers (Fig. 11), cross
heads and push rods (Fig. 12). Mark each component
so they can be installed in their original positions.
NOTE: The #5 cylinder exhaust and the #6 cylinder
intake and exhaust push rods are removed by lift-
ing them up and through the provided cowl panel
access holes. Remove the rubber plugs to expose
these relief holes.
(39) Remove the fuel return line and banjo bolt at
the rear of the cylinder head. Be careful not to drop
the two (2) sealing washers.
(40) Remove the fuel injectors (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/FUEL INJECTOR -
REMOVAL).
(41) Remove rocker housing bolts and rocker hous-
ing and gasket.(42) Reinstall the engine lift bracket at the rear of
cylinder head. Torque to 77 N´m (57 ft. lbs.).
(43) Remove twenty six (26) cylinder head-to-block
bolts.
(44) Attach an engine lift crane to engine lift
brackets and lift cylinder head off engine and out of
vehicle.
(45) Remove the head gasket and inspect for fail-
ure.
CLEANING
CLEANINGÐCYLINDER HEAD
CAUTION: Do not wire brush head surface while
fuel injectors are still installed. Fuel injector dam-
age can result.
Remove fuel injector before cleaning (if not already
removed during cylinder head removal).
Clean the carbon from the injector nozzle seat with
a nylon or brass brush.
Scrape the gasket residue from all gasket surfaces.
Wash the cylinder head in hot soapy water solution
(88ÉC or 140ÉF).
After rinsing, use compressed air to dry the cylin-
der head.
Polish the gasket surface with 400 grit paper. Use
an orbital sander or sanding block to maintain a flat
surface.
CLEANINGÐCROSSHEADS
Clean all crossheads in a suitable solvent. If neces-
sary, use a wire brush or wheel to remove stubborn
deposits. Rinse in hot water and blow dry with com-
pressed air.
Fig. 11 Rocker Arm and Pedestal Removal
1 - ROCKER ARM
2 - PEDESTAL
Fig. 12 Push Rod Removal
DRENGINE 5.9L DIESEL 9 - 251
CYLINDER HEAD (Continued)

(9) Install rocker housing and bolts. Tighten to 24
Nm (18 lb. ft.).
(10) Install fuel injector(Refer to 14 - FUEL SYS-
TEM/FUEL INJECTION/FUEL INJECTOR -
INSTALLATION).
(11) Install injector harness nuts. Tighten to 1.25
Nm (11 lb. in.).
(12) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(13) Install wire harness P-clip to cylinder head
behind filter housing 24 N´m (18 ft. lbs.).
(14) Connect the IAT/MAP sensor connector.
(15) Install the fuel filter canister assembly and
torque mounting bolts to 24 N´m (18 ft. lbs.).
(16) Connect fuel lift pump, WIF sensor, and fuel
heater.
(17) Remove the engine lift bracket at rear of cyl-
inder head.
CAUTION: Failure to follow procedure will result in
fuel leaks and/or fuel system failure.
(18)Install the fuel rail and high pressure
fuel lines as follows:
(a) Hand tighten fuel rail bolts.
(b) Hand tighten fuel drain line to pressure lim-
iting valve. Hand tighten banjo bolt at fuel filter
housing.
(c) Hand tighten fuel rail-to-cylinder head high
pressure fuel lines.(d) Install fuel line brace bolts-to-intake mani-
fold finger tight.
(e) Hand tighten fuel pump to fuel rail line.
(f) Torque fuel line nuts at cylinder head to 30
Nm ( 22 ft. lbs.).
(g) Torque fuel line nuts at fuel rail to 30 Nm
(22 ft. lbs.)
(h) Using a back up wrench, torque fuel pump to
fuel rail line to 37 Nm (27 ft. lbs.). At injection
pump.
(i) Torque fuel pump to fuel rail line to 37 Nm
(27 ft. lbs.) at fuel rail.
(j) Torque fuel drain banjo bolt at pressure lim-
iting valve and front of fuel filter housing to 24 Nm
(18 ft. lbs.).
(k) Torque fuel line brace bolts to 24 N´m (18 ft.
lbs.).
(l) Torque rail bolts to 24 Nm (18 ft. lbs.).
(m) Connect fuel pressure sensor.
(19) Install the engine lift bracket at the rear of
cylinder head. Torque to 77 N´m (57 ft. lbs.).
(20) Reposition number 6 fuel line shield and
torque to 43 N´m (32 ft. lbs.).
(21) Install the fuel filter to injection pump low
pressure line. Inspect and replace sealing washers if
necessary. Torque banjo bolts to 24 N´m (18 ft. lbs.).
(22) Connect fuel return line at back of cylinder
head hand tight.
(23) Connect fuel return line at filter housing hand
tight.
(24) Torque banjo connections at cylinder head and
fuel filter housing to 24 Nm (18 ft. lbs.)
(25) Install bracket to rear of filter housing.
Torque to 24 Nm (18 ft. lbs.).
(26) Using new gaskets, install the intake grid
heater and air inlet housing. Torque bolts to 24 N´m
(18 ft. lbs.).
(27) Install wire harness P-clip and push on clip to
air inlet housing.
(28) Connect engine oil level indicator tube at fuel
filter housing and at air inlet housing.
(29) Connect the APPS connector.
(30) Install the APPS assembly to the cylinder
head bracket and torque bolts to 24 N´m (18 ft. lbs.).
(31) Install the throttle linkage cover.
(32) Install the charge air cooler-to-air inlet hous-
ing duct assembly. Torque all clamps to 11 N´m (100
in. lbs.).
(33) Connect intake grid heater wires.
(34) Secure engine harness to front of cylinder
head with bolt at four locations.
(35) Connect engine coolant temperature sensor
connector.
(36) Connect radiator upper hose to thermostat
housing.
Fig. 20 Rocker Arm and Pedestal Removal
1 - ROCKER ARM
2 - PEDESTAL
9 - 254 ENGINE 5.9L DIESELDR
CYLINDER HEAD (Continued)

INSTALLATION
(1) Install new valve seals. The yellow seals are for
the intake valves and the green seals are for the
exhaust valves.
(2) Install the valves in their original postion. The
exhaust valves are identified by a dimple on the
valve head (Fig. 31).
(3) Install the valve springs and retainer.
(4) Install the valve spring compressor tool 8319±A
as shown in (Fig. 22) and (Fig. 23).
(5) Compress the valve springs and install the
valve retaining locks (Fig. 24).
(6) Remove the compressor and repeat the proce-
dure on the remaining cylinders.
(7) Install new o-ring and sealing washer on injec-
tor.
(8) Lubricate o-ring and injector bore.
(9) Verify sealing washer (shim) was removed with
old injector.
(10) Install injector Refer to (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/FUEL INJECTOR -
INSTALLATION).
(11) Install the cylinder head (Refer to 9 -
ENGINE/CYLINDER HEAD - INSTALLATION).
STANDARD PROCEDURE - VALVE LASH
ADJUSTMENT AND VERIFICATION
NOTE: To obtain accurate readings, valve lash mea-
surements AND adjustments should only be per-
formed when the engine coolant temperature is less
than 60É C (140É F).
The 24±valve overhead system is a ªlow-mainte-
nanceº design. Routine adjustments are no longer
necessary, however, measurement should still takeplace when trouble-shooting performance problems,
or upon completion of a repair that includes removal
and installation of the valve train components or
injectors.
(1) Disconnect battery negative cables.
(2) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(3) Using the crankshaft barring tool #7471±B,
rotate crankshaft to align damper TDC mark to
12:00 o'clock position.
(a) If both number one cylinder rocker levers are
loose, continue to next step.
(b) If both number one clylinder rocker levers
are not loose, rotate crankshaft 360 degrees.
(4) With the engine in this position, valve lash can
be measured at the following rocker arms:INTAKE
1±2±4 / EXHAUST 1±3±5. Measure the valve lash by
inserting a feeler gauge between the rocker arm
socket and crosshead (Fig. 32). Refer to VALVE
LASH LIMIT CHART for the correct specifications. If
the measurement fallswithinthe limits, adjust-
ment/resettingis notnecessary. If measurement
finds the lashoutsideof the limits, adjustment/re-
settingisrequired.
VALVE LASH LIMIT CHART
INTAKE EXHAUST
0.152 mm ( 0.006 in.)
MIN.0.381 mm (0.015 in.)
MIN.
0.381 mm (0.015 in.)
MAX.0.762 mm (0.030 in.)
MAX.
note:
If measured valve lash falls within these
specifications, no adjustment/reset is necessary.
Engine operation within these ranges has no adverse
affect on performance, emissions, fuel economy or
level of engine noise.
(5) If adjustment/resetting is required, loosen the
lock nut on rocker arms and turn the adjusting screw
until the desired lash is obtained:
²INTAKE0.254 mm (0.010 in.)
²EXHAUST0.508 mm (0.020 in.) Tighten the
lock nut to 24 Nm (18 ft. lbs.) and re-check the valve
lash.
(6) Using the crankshaft barring tool, rotate the
crankshaftone revolution (360É) to align the
damper TDC mark to the 12 o'clock position.
Fig. 31 Valve Identification
1 - INTAKE VALVES
2 - EXHAUST VALVES
DRENGINE 5.9L DIESEL 9 - 259
INTAKE/EXHAUST VALVES & SEATS (Continued)

(13) Install the cooling fan (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - INSTALLATION).
(14) Connect battery negative cables.
(15) Start engine and check for oil leaks.
INTAKE MANIFOLD
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove the charge air cooler outlet tube from
the air inlet housing (Fig. 118).
(3) Remove the engine oil dipstick tube mounting
bolt (Fig. 118).
(4) Remove dipstick support at fuel filter housing.
Position dipstick tube to the side.
(5) Disconnect the air grid heater power cables at
the cable mounting studs.
(6) Disconnect the ground strap at the intake
cover.
(7) Remove the engine wiring harness connections
at the air inlet housing elbow.
(8) Remove the four (4) air inlet housing mounting
bolts and remove the housing from top of the heater
elements.
(9) Remove the intake air grid heater from the
manifold (Fig. 119).
(10) Remove the high pressure fuel lines and fuel
rail (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
FUEL LINES - REMOVAL).
(11) Remove APPS bracket from cylinder head to
gain access to front intake manifold cover bolts.
(12) Disconnect manifold air temperature/pressure
sensor connector.
(13) Remove the remaining intake manifold cover-
to-cylinder head bolts.
(14) Remove the intake manifold cover and gasket.
Keep the gasket material and any other material out
of the air intake.
(15) Clean the intake manifold cover and cylinder
head sealing surface.
CLEANING
Clean manifold in solvent and blow dry with com-
pressed air.
Clean cylinder block gasket surfaces using a suit-
able solvent.
The plenum pan rail must be clean and dry (free of
all foreign material).
INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straightedge.
Fig. 118 Charge Air Cooler Air Tube
1 - FRONT WIRING CLIP
2 - GROUND CABLE
3 - TUBE BOLT
4 - ENGINE OIL DIPSTICK TUBE
5 - CLAMPS
6 - AIR TUBE (INT. MAN.-TO-INTERCOOLER)
7 - RUBBER HOSE
8 - AIR INTAKE HOUSING
9 - CABLE BRACKET HOUSING
Fig. 119 Intake Air Grid Heater
1 - INTAKE AIR GRID HEATER
2 - GASKET
DRENGINE 5.9L DIESEL 9 - 297
OIL PUMP (Continued)

INSTALLATION
(1) Using a new gasket, install the intake manifold
cover.
(2) Install the cover-to-cylinder head bolts that do
not hold down the fuel rail. Tighten the bolts to 24
N´m (18 ft. lbs.) torque.
(3) Install the high pressure rail and fuel lines
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
FUEL LINES - INSTALLATION).
(4) Using two (2) new gaskets, install the intake
air grid heater and air inlet housing. Position the
ground cable and install and tighten the bolts to 24
N´m (18 ft. lbs.) torque.
(5) Connect the manifold air temperature/pressure
sensor connector.
(6) Install and tighten the air intake heater power
supply nuts to 14 N´m (120 in. lbs.) torque.
(7) Install the APPS bracket. Torque fasteners to
43 N´m (32ft lbs.) torque.
(8) Install oil dipstick tube support at fuel filter
housing.
(9) Install the engine oil dipstick tube and mount-
ing bolt.
(10) Position the charge air cooler outlet tube onto
the air inlet housing. Tighten the clamps to 11 N´m
(100 in. lbs.) torque.
(11) Attach the engine wire harness to the air inlet
housing at two locations.
(12) Prime the fuel system. Refer to the fuel prim-
ing procedure in Group 14, Fuel System.
(13) Connect the battery negative cables.
EXHAUST MANIFOLD
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise vehicle on hoist.
(3) Disconnect the exhaust pipe from the turbo-
charger elbow.
(4) Disconnect oil drain tube from turbocharger.
(5) Lower vehicle.
(6) Disconnect the turbocharger air inlet hose.
(7) Remove air cleaner assembly.
(8) Disconnect the turbocharger oil supply line.
(9) Disconnect the charge air cooler inlet pipe from
the turbocharger.
(10) Remove the turbocharger and gasket from the
exhaust manifold.
(11) Remove the cab heater return pipe nuts from
the exhaust manifold stud. Position the tube out of
the way.
(12) Remove heat shield.
(13) Remove exhaust manifold bolt lockplates.
(14) Remove the exhaust manifold-to-cylinder head
bolts and spacers (Fig. 120).(15) Remove the exhaust manifold and gaskets
(Fig. 120).
CLEANING
Clean the cylinder head and exhaust manifold seal-
ing surfaces with a suitable scraper. Use a Scotch-
BriteŸ pad or equivalent.
INSPECTION
Inspect the exhaust manifold for cracks. Measure
the exhaust manifold for flatness. Place a ruler over
all of the exhaust ports and insert a feeler gauge
between the port flange and the ruler. Maximum
deviation from flat is 0.20 mm (.008 inch).
INSTALLATION
(1) Using new gaskets, install the exhaust mani-
fold and gaskets. Install the bolts and spacers and
tighten the bolts in the sequence shown in to 43 N´m
(32 ft. lbs.) torque.
(2) Retorque the four center bolts.
Fig. 120 Exhaust Manifold and Gaskets
1 - RETAINING STRAP
2 - BOLT (7)
3 - SPACER
4 - MANIFOLD, EXHAUST
5 - GASKET
6 - BOLT (5)
9 - 298 ENGINE 5.9L DIESELDR
INTAKE MANIFOLD (Continued)

(3) Install heat shield and torque nuts to 15 Nm
(11 ft. lbs.).
(4) Install cab heater tube.
(5) Install exhaust manifold bolt retention straps.
(6) Install the cab heater return hose to the man-
ifold bolt stud. Tighten the nut to 24 N´m (18 ft. lbs.)
torque.
(7) Install the turbocharger and a new gasket.
Apply anti-seize to the studs and then tighten the
turbocharger mounting nuts to 43 N´m (32 ft. lbs.)
torque.
(8)Pre-lube the turbocharger.Pour 50 to 60 cc
(2 to 3 oz.) clean engine oil in the oil supply line fit-
ting on the turbo. Rotate the turbocharger impeller
by hand to distrubute the oil thoroughly.
(9) Install and tighten the oil supply line fitting
nut to 24 N´m (18 ft. lbs.) torque.
(10) Position the charge air cooler inlet pipe to the
turbocharger. With the clamp in position, tighten the
clamp nut to 11 N´m (100 in. lbs.) torque.
(11) Position the air inlet hose to the turbocharger.
Tighten the clamp to 11 N´m (100 in. lbs.) torque.
(12) Raise vehicle on hoist.
(13) Install the oil drain tube and a new gasket to
the turbocharger. Tighten the drain tube bolts to 24
N´m (18 ft. lbs.) torque.
(14) Connect the exhaust pipe to the turbocharger
and tighten the bolts to 11 N´m (100 ft. lbs.) torque.
(15) Lower the vehicle.
(16) Connect the battery negative cables.
(17) Start the engine to check for leaks.
VALVE TIMING
STANDARD PROCEDURE - TIMING
VERIFICATION
(1) Remove the cylinder head cover(Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(2) Remove fuel injector from cylinder number
1(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
FUEL INJECTOR - REMOVAL).
(3) Using Special Tool 7471B rotate the engine
until the TDC mark on the damper is at 12 o'clock.
(4) Using a 8 in.x 1/4 in. dowel rod inserted into
cylinder number 1, rock the crankshaft back and
forth to verify piston number 1 is at TDC.
(5) With cylinder number still at TDC, inspect the
keyway on the crankshaft gear for proper alignment
(12 o'clock position).
(6) If the keyway is not at 12 o'clock position
replace the crankshaft gear assembly.
(7) If the keyway is at 12 o'clock position, remove
front gear cover and verify timing mark alignmentbetween the camshaft gear and crankshaft gear, if
not aligned inspect keyway on camshaft gear.
(8) Inspect keyway on camshaft gear for proper
alignment with the key in the camshaft, if alignment
is off replace the camshaft/gear assembly.
(9) If timing marks alignment is off and no dam-
age is found at either the crankshaft or camshaft
gear keyways, realign timing marks as necessary.
GEAR HOUSING
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise vehicle on hoist.
(3) Partially drain engine coolant into container
suitable for re-use (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
(4) Lower vehicle.
(5) Remove radiator upper hose.
(6) Disconnect coolant recovery bottle hose from
radiator filler neck and lift bottle off of fan shroud.
(7) Disconnect windshield washer pump supply
hose and electrical connections and lift washer bottle
off of fan shroud.
(8) Remove lower fan shroud fasteners. Disconnect
fan drive wire harness.
(9) Remove the upper fan shroud-to-radiator
mounting bolts.
(10) Remove viscous fan/drive assembly (Refer to 7
- COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(11) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(12) Remove the cooling fan support/hub from the
front of the engine.
(13) Raise the vehicle on hoist.
(14) Remove the crankshaft damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL) and speed indicator ring.
(15) Lower the vehicle.
(16) Remove the power steering pump.
(17) Remove the accessory drive belt tensioner.
(18) Remove the gear cover-to-housing bolts and
gently pry the cover away from the housing, taking
care not to mar the gasket surfaces.
(19) Remove the fuel injection pump (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - REMOVAL).
(20) Disconnect the camshaft position sensor con-
nector.
(21) Disconnect and remove engine speed sensor.
(22) Remove the camshaft (Refer to 9 - ENGINE/
ENGINE BLOCK/CAMSHAFT & BEARINGS (IN
BLOCK) - REMOVAL).
(23) Remove the six front oil pan fasteners.
DRENGINE 5.9L DIESEL 9 - 299
EXHAUST MANIFOLD (Continued)

(24) Remove the gear housing fasteners.
NOTE: Use care when removing the gear housing,
to avoid damage to the oil pan gasket, as the gas-
ket will be reused if it is not damaged.
(25) Slide a feeler gauge between the gear housing
and oil pan gasket, to break the gasket seal.
(26) Remove the gear housing and gasket.
(27) Clean the gasket material from the cylinder
block and gear housing.
INSTALLATION
(1) Inspect oil pan gasket. If torn, gasket must be
replaced.
(2) Install a new gear housing gasket onto cylinder
block and trim any excesss gasket material flush to
oil pan rail.
(3) Install the gear housing. Torque bolts to 24
N´m (18 ft. lbs.) (Fig. 121).
(4) If a new housing is installed, the camshaft
position sensor, and engine speed sensor must be
transferred to the new housing.
(5) Connect the camshaft position sensor connec-
tor.
(6) Install and connect engine speed sensor.
(7) Install the injection pump (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/FUEL INJECTION
PUMP - INSTALLATION).
(8) Install the camshaft (Refer to 9 - ENGINE/EN-
GINE BLOCK/CAMSHAFT & BEARINGS (INBLOCK) - INSTALLATION). Align the crankshaft
and camshaft gear marks as shown in (Fig. 122).
(9) Install a new front crankshaft seal into the
gear cover.
(10) Apply a bead of MopartSilicone Rubber
Adhesive Sealant or equivalent to the gear housing
cover. Be sure to surround all through holes.
(11) Using the seal pilot to align the cover, install
the cover to the housing and install the bolts.
Tighten the bolts to 24 N´m (18 ft. lbs.) torque.
(12) Remove the seal pilot. Install front seal dust
shield.
(13) Raise the vehicle.
(14) Trim any excess gear housing gasket to make
it flush with the oil pan rail.
(15) Install the crankshaft damper and speed indi-
cator ring (Refer to 9 - ENGINE/ENGINE BLOCK/
VIBRATION DAMPER - INSTALLATION). Torque
bolts to 40 Nm (30 ft. lbs.), plus an additional 60É.
(16) Lower vehicle.
(17) Install the fan support/hub assembly and
tighten bolts to 32 N´m (24 ft. lbs.) torque.
(18) Install the power steering pump.
(19) Install the accessory drive belt tensioner.
Torque bolt to 43 N´m (32 ft. lbs.) torque.
(20) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(21) Install the upper cooling fan and shroud
together (Refer to 7 - COOLING/ENGINE/RADIA-
TOR FAN - INSTALLATION).
(22) Install lower shroud and connect fan drive
harness connector.
Fig. 121 GEAR HOUSING CAPSCREW TORQUE
SEQUENCE
Fig. 122 Timing Mark Alignment
9 - 300 ENGINE 5.9L DIESELDR
GEAR HOUSING (Continued)

SPECIAL TOOLS
CATALYTIC CONVERTER
DESCRIPTION - CATALYTIC CONVERTER
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER WORK AROUND OR ATTEMPT
TO SERVICE ANY PART OF THE EXHAUST SYSTEM
UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE
TAKEN WHEN WORKING NEAR THE CATALYTIC
CONVERTER. THE TEMPERATURE OF THE CON-
VERTER RISES TO A HIGH LEVEL AFTER A SHORT
PERIOD OF ENGINE OPERATION TIME.
CAUTION: DO NOT remove spark plug wires from
plugs or by any other means short out cylinders.
Failure of the catalytic converter can occur due to a
temperature increase caused by unburned fuel
passing through the converter.
The stainless steel catalytic converter body is
designed to last the life of the vehicle. Excessive heat
can result in bulging or other distortion, but exces-
sive heat will not be the fault of the converter. If
unburned fuel enters the converter, overheating may
occur. If a converter is heat-damaged, correct the
cause of the damage at the same time the converter
is replaced. Also, inspect all other components of the
exhaust system for heat damage.
Unleaded gasoline must be used to avoid con-
taminating the catalyst core.
50 State emission vehicles incorporate two mini
catalytic converters located after the exhaust mani-
folds and before the inline catalytic converter.
OPERATION
The catalytic converter captures and burns any
unburned fuel mixture exiting the combustion cham-
bers during the exhaust stroke of the engine. This
process aids in reducing emissions output.
REMOVAL
REMOVAL
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
(1) Raise and support the vehicle.
(2) Saturate the bolts and nuts with heat valve
lubricant. Allow 5 minutes for penetration.
(3) Remove the bolts from the crossover pipe to the
catalytic converter connection.
(4) Disconnect oxygen sensor wiring.
(5) Loosen the nuts from the clamp that hold the
catalytic converter to the exhaust pipe flange connec-
tion.
NOTE: Do not remove nut from T-Bolt. Only remove
nut far enough, so that the T end can be removed
from the clamp.
(6) Remove the T bolt end of the fastener, from the
clamp.
(7) Spread the clamp, and remove the catalytic
converter from the vehicle.
(8) Discard the clamp.
NOTE: The catalytic converter to exhaust manifold
clamp is not reusable. Always use a new clamp
when reinstalling the catalytic converter.
REMOVAL
(1) Raise and support vehicle.
(2) Saturate the bolts and nuts with heat valve
lubricant. Allow 5 minutes for penetration.
(3) Remove clamps and nuts.
(4) Remove the catalytic converter.
INSPECTION
Look at the stainless steel body of the converter,
inspect for bulging or other distortion that could be a
result of overheating. If the converter has a heat
shield attached make sure it is not bent or loose.
If you suspect internal damage to the catalyst, tap-
ping the bottom of the catalyst with a rubber mallet
may indicate a damaged core.
INSTALLATION
INSTALLATION
NOTE: The catalytic converter to exhaust manifold
clamp is not reusable. Always use a new clamp
when reinstalling the catalytic converter.
TURBOCHARGER TESTER 9022
11 - 6 EXHAUST SYSTEMDR
EXHAUST SYSTEM (Continued)

(6) Full load boost pressure at rated speed will be
158 - 186 kPa (23 - 27 psi.) depending on engine hp
rating.. If pressure readings are are not within this
range inspect for the following:
²Restricted air inlet system
²Leak in the charge air cooler system (Refer to 11
- EXHAUST SYSTEM/TURBOCHARGER SYSTEM/
CHARGE AIR COOLER AND PLUMBING - DIAG-
NOSIS AND TESTING)
²Turbocharger wastegate broken or misadjusted
²Restricted/high pressure drop across charge air
cooler
²Turbocharger damaged (Refer to 11 - EXHAUST
SYSTEM/TURBOCHARGER SYSTEM/TURBO-
CHARGER - INSPECTION)
TURBOCHARGER
DESCRIPTION
The turbocharger is an exhaust-driven super-
charger which increases the pressure and density of
the air entering the engine. With the increase of air
entering the engine, more fuel can be injected into
the cylinders, which creates more power during com-
bustion.
The turbocharger assembly consists of four (4)
major component systems (Fig. 14) (Fig. 15) :²Turbine section
²Compressor section
²Bearing housing
²Wastegate
Fig. 13 INTAKE MANIFOLD TO AIR INLET DUCT
RUBBER SLEEVE
1 - INTAKE MANIFOLD AIR INLET
2 - CLAMPS
3 - AIR INLET DUCT
4 - AIR INLET DUCT RUBBER SLEEVE
Fig. 14 Turbocharger Operation
1 - TURBINE SECTION
2 - EXHAUST GAS
3 - BEARING HOUSING
4 - COMPRESSOR SECTION
5 - INLET AIR
6 - COMPRESSED AIR TO ENGINE
7 - EXHAUST GAS
8 - EXHAUST GAS TO EXHAUST PIPE
Fig. 15 Turbocharger Wastegate Actuator
1 - TURBOCHARGER
2 - DIAPHRAGM
3 - WASTE GATE ACTUATOR
11 - 12 EXHAUST SYSTEMDR
TURBOCHARGER SYSTEM (Continued)

(2)Pre-lube the turbocharger.Pour 50 to 60 cc
(2 to 3 oz.) clean engine oil in the oil supply line fit-
ting. Carefully rotate the turbocharger impeller by
hand to distribute the oil thoroughly.
(3) Install and tighten the oil supply line to 24
N´m (18 ft. lbs.) torque.
(4) Position the charge air cooler inlet pipe to the
turbocharger. With the clamp in position, tighten the
clamp nut to 11 N´m (95 in. lbs.) torque.
(5) Position the air inlet hose to the turbocharger
(Fig. 18). Tighten the clamp to 11 N´m (95 in. lbs.)
torque.
(6) Raise vehicle on hoist.
(7) Using a new gasket, install the oil drain tube
to the turbocharger (Fig. 19). Tighten the drain tube
bolts to 24 N´m (18 ft. lbs.) torque.
(8) Tighten the oil drain tube clamps to 8 N´m (71
in. lbs.).
(9) Connect the exhaust pipe to the turbocharger
and tighten the bolts to 11.3 N´m (100 in. lbs.)
torque.
(10) Lower the vehicle.
(11) Connect the battery negative cables.
(12) Start the engine to check for leaks.
CHARGE AIR COOLER AND
PLUMBING
DESCRIPTION
The charge air system (Fig. 23) consists of the
charge air cooler piping, charge air cooler and intake
air grid heater.The charge air cooler is a heat exchanger that uses
air flow from vehicle motion to dissipate heat from
the intake air. As the turbocharger increases air
pressure, the air temperature increases. Lowering
the intake air temperature increases engine effi-
ciency and power.
OPERATION
Intake air is drawn through the air cleaner and
into the turbocharger compressor housing. Pressur-
ized air from the turbocharger then flows forward
through the charge air cooler located in front of the
radiator. From the charge air cooler the air flows
back into the intake manifold.
DIAGNOSIS AND TESTING - CHARGE AIR
COOLER SYSTEM - LEAKS
Low turbocharger boost pressure and low engine
performance can be caused by leaks in the charge air
cooler or plumbing. Fuel staining on the exhaust
manifold can also be an indication that there are
leaks in the air system.The following procedure out-
lines how to check for leaks in the charge air cooler
system.
(1) Loosen clamp and remove air inlet hose from
turbocharger.
(2) Insert Special Tool 9022 Adapter into the tur-
bocharger inlet. Tighten tool clamp to 8 N´m (72 in.
lbs.).
Fig. 22 Measure Turbocharger Bearing Radial
Clearance
1 - FEELER GAUGE
Fig. 23 Intake Air Circulation
1 - CHARGE AIR COOLER
2 - AIRFILTER
3 - TURBOCHARGER
11 - 16 EXHAUST SYSTEMDR
TURBOCHARGER (Continued)