1993 DODGE TRUCK Service Repair Manual

11-18 EXHAUST
SYSTEM
AND
INTAKE MANIFOLD

MUFFLER
REAR

SUPPORT
BRACKET
MUFFLER
FRONT
SUPPORT BRACKET

159"
W.B.)-2
REQUIRED

MUFFLER

INSULATOR
FRAME

RAIL

/

SHOULDER
BOLT

MUFFLER

INSULATOR
MUFFLER
FRONT
SUPPORT BRACKET
(131", 135" & 149" W.B.] 1 REQUIRED
SHOULDER BOLTS
J9211-26

Fig.
4 Muffler Front/Rear
Support
Brackets (3) Remove the shoulder bolts from the muffler
front and rear support brackets (Fig. 4).
(4) Separate the extension(s) and the muffler from
the exhaust tailpipe and the front exhaust pipe.
(5) If required, remove the muffler support bracket
from the frame rail (Fig. 4).
INSTALLATION (1) If removed, install the muffler support bracket
to the frame rail. Tighten the bolts to 28 Nun (250 in. lbs.) torque.
(2) Align the extension(s) and the muffler with the
front exhaust pipe and the exhaust tailpipe.
(3) Install the shoulder bolts through the insula­
tors and into the muffler front and rear support
brackets (Fig. 4). Tighten the bolts to 28 N-m (250 in. lbs.) torque.
(4) Position the clamps onto the front exhaust ex­
tension pipe. Tighten the nuts to 54 Nun (40 ft. lbs.) torque.
(5) Position the clamps onto the rear exhaust ex­
tension pipe or onto the muffler rear extension pipe.
Tighten the nuts to 54 Nun (40 ft. lbs.) torque.
(6) Lower the vehicle. (7) Start the engine and check for leaks.

EXHAUST
TAILPIPE

REMOVAL (1) Raise and support the vehicle.
(2) Remove the clamp from the pipe (Fig. 5).
(3) Remove the bolt from the exhaust tailpipe
bracket. (4) Separate the exhaust tailpipe from the rear ex­
tension pipe or from the muffler rear extension pipe. (5) If required, remove the exhaust tailpipe
bracket from the frame rail (Fig. 5).
TAIL
PIPE
BRACKET
J9211-25

Fig.
5
Exhaust
Tailpipe
INSTALLATION
(1) If removed, install the exhaust tailpipe bracket
to the frame rail. Tighten the bolts to 23 Nun (200 in. lbs.) torque. (2) Position the exhaust tailpipe into the rear ex­
tension pipe or the muffler rear extension pipe. (3) Install the bolt into the exhaust tailpipe
bracket. Tighten the bolt to 23 Nun (200 in lbs.) torque.
(4) Position the clamp onto the exhaust tailpipe.
Tighten the bolts to 54 Nun (40 ft. lbs.) torque.
(5) Lower the vehicle.
(6) Start the engine and check for leaks.

ENGINE
EXHAUST MANIFOLD

REMOVAL (1) Disconnect the air intake and exhaust pipes
(Fig. 6). (2) Disconnect the turbocharger oil supply line and
the oil drain tube from the turbocharger (Fig. 7). (3) Disconnect the charge air cooler (intercooler)
inlet duct from the turbocharger (Fig. 7). (4) Remove the turbocharger and gasket. (5) Remove the cab heater supply and return lines.
(6) Remove the engine exhaust manifold and gas­
kets (Fig. 8). (7) Clean the sealing surfaces.
INSTALLATION (1) Install the engine exhaust manifold and gas­

kets.
Tighten the exhaust manifold bolts in sequence
to 43 Nun (32 ft. lbs.) torque (Fig. 9). (2) Install the turbocharger. Tighten the turbo­
charger mounting nuts to 32 Nun (24 ft. lbs.) torque.

EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 19

EXHAUST

MANIFOLD
GASKET

J9111-52
Fig.
6 Air intake Pipe,
Exhaust
Pipe and
Turbocharger
,
till
TURBOCHARGER,

OIL SUPPLY
UNE

^J9111-53

Fig.
7
OH
Supply Line and Charge Air Cooler (intercooler) inlet
Duct

(3) Position the charge air cooler (intercooler) inlet
duct to the turbocharger. With the clamp in position,
tighten the clamp nut to 8 Nun (72 in. lbs.) torque.
(4) Position the air intake pipe and the exhaust
pipe onto the turbocharger. Tighten the clamps to 8 Nun (74 in. lbs.) torque.
(5) Install the oil drain tube and oil supply line to
the turbocharger. Tighten the drain tube bolts to 24
J9111-5

Fig.
8
Engine
Exhaust
Manifold and
Gaskets

EXHAUST

MANIFOLD^^^^
GASKET

J9111-6

Fig.
9
Engine
Exhaust
Manifold
Bolt
Tightening
Sequence

Nun (18 ft. lbs.) torque. Tighten the oil supply line
fitting nut to 15 Nun (11 ft. lbs.) torque. (6) Connect the cab heater supply and return lines.
Tighten the line nuts to 24 Nun (18 ft. lbs.) torque. (7) Operate the engine to check for leaks.
INTAKE MANIFOLD COVER / AIR INTAKE HEATER
REMOVAL (1) Remove the charge air cooler (intercooler) out­
let duct from the air inlet tube (Fig. 10). (2) Remove the high pressure fuel lines. (3) Disconnect and remove the air intake heater
ground wire (Fig. 10). (4) Disconnect the air intake heater power supply
lines (Fig. 11). Remove the air intake heater and
gaskets (Fig. 11). Clean the mounting surface of the
intake manifold cover. (5) Disconnect the charge air temperature sensor
from the intake manifold cover (Fig. 12). (6) Disconnect the air temperature switch from the
intake manifold cover (Fig. 12).

11-20 EXHAUST
SYSTEM
AND
INTAKE MANIFOLD
AIR INLET
INTERCOOLER/ OUTLET DUCT
X^l
/J9111-54.

Fig.
10 Air Inlet Tube and Heater
Ground
Wire
J9111-51

Fig.
11 Air Intake Heater (7) Disconnect the fuel heater ground wire from in­
take manifold cover (Fig. 13).
(8) Remove the manifold intake cover and gasket
(Fig. 13). Keep the gasket material and any other
material out of the air intake.
(9) Clean the sealing surface.

INSTALLATION
(1) Using a new gasket, install the intake manifold
cover. (2) Install the fuel heater ground wire. Tighten the
bolt to 12 Nun (110 in. lbs.) torque.
(3) Connect the air temperature switch to the in­
take manifold cover.
(4) Connect the charge air temperature sensor to
the intake manifold cover.
AIR
TEMPERATURE
SWITCH

(KSB
SOLENOID)

J9114-235

Fig.
12
Charge
Air
Temperature
Sensor
and Air
Temperature
Switch

AAANIFOLD INTAKE COVER FUEL HEATER
GROUND WIRE

J9111-50

Fig.
13 Manifold Intake
Cover
and
Fuel
Heater
Ground
Wire
(5) Some of the intake manifold bolt holes are
drilled through and must be sealed. Apply liquid te­
flon sealant to the bolts. Install the intake manifold
cover bolts. Tighten the bolts to 24 Nun (18 ft. lbs.)
torque.
(6) Install a new gasket between the air intake
heater and the intake manifold cover. Install a new gasket on top of the air intake heater.
(7) Install the air inlet tube. Tighten the air inlet
tube bolts to 24 Nun (18 ft. lbs.) torque. (8) Connect the intake manifold heater ground

wire.
(9) Install and tighten the air intake heater power
supply nuts to 14 Nun (10 ft. lbs.) torque. (10) Position the charge air cooler (intercooler) out­
let duct onto the air inlet tube. Tighten the charge air cooler (intercooler) outlet duct clamps to 8 Nun (74 in. lbs.) torque. (11) Install and bleed the high pressure fuel lines.
Tighten the high pressure fuel line nuts to 24 Nun (18 ft. lbs.) torque.

•

EXHAUST
SYSTEM
AND
INTAKE
MANIFOLD
11 - 21
TURBOCHARGER

REMOVAL (1) Disconnect the negative cable from the battery. (2) Disconnect the air intake pipe and exhaust pipe
(Fig. 14).

Fig.
14 Air Intake Pipe,
Exhaust
Pipe and Turbocharger
(3) Remove the oil drain tube bolts.
(4) Remove the oil supply line (Fig. 15).
(5) Disconnect the charge air cooler (intercooler)
inlet duct from the turbocharger (Fig. 15).
(6) Remove the turbocharger mounting nuts and
the turbocharger.

(7)
If the turbocharger is not to be installed imme­
diately, cover the opening to prevent material from
entering into the manifold.
(8) Clean and inspect the sealing surface.

DISASSEMBLY
(1) Scribe the housing so they can be assembled in
the same position.
(2) Clamp the turbocharger in a bench vise.
(3) Remove the compressor housing V-Band clamps
(Fig. 16). (4) Remove the compressor housing and inspect for
impeller contact (Fig. 16). (5) Remove the square cut O-ring (Fig. 16). (6) Remove the impeller nut (Fig. 16). Turn the
impeller nut to the right to loosen. The nut and shaft
have left hand threads. (7) Remove the impeller and inspect the blades for
damage. The wheel and shaft assembly is balanced as a unit. If the impeller is damaged the complete as­
sembly must be replaced.
Fig.
16
Compressor
Housing
and Impeller
(8) Remove the diffuser bolts and lockplate (Fig.

17).
(9) Remove the diffuser and discard the O-ring
(Fig. 18). (10) Remove the oil slinger and discard the piston
ring (Fig. 18).
(11) Inspect for cracks and excessive wear.
(12) Remove the oil baffle (Fig. 19).
(13) Remove the thrust bearing and retainer
screws (Fig. 19). Do not reuse the thrust bearing. (14) Remove the thrust collar (Fig. 19).
(15) Inspect the collar for excessive wear.
(16) Remove the turbine housing lock plates and
clamp plates (Fig. 20). (17) Remove the bearing housing (Fig. 20).

11
- 22
EXHAUST
SYSTEM
AND
INTAKE MANIFOLD

•

DIFFUSER
TURBINE
HOUSING
O-RING BEARING
HOUSING
LOCKPLATE
J9111-9

Fig.
17 Diffuser and Lockplate
OIL
SLINGER

MO
Fig.
18 Diffuser,
O-Ring
and Oil
Slinger

THRUST
COLLAR
OIL
BAFFLE

J9111-11

Fig.
19 Oil
Baffle,
Thrust Bearing and Collar
(18) Remove the turbine shaft and heat shield
(Fig. 21).
(19) Inspect the turbine blades and the shaft for
excessive wear.
LOCK
PLATE

J9111-12
Fig.
20 Turbine
Housing Lock
Plates and
Clamp
Plates

TURBINE WHEEL SHAFT
PISTON RING TYPE SEAL

J9111-13
HEAT
SHIELD Fig.
21 Turbine
Wheel
Shaft and Heat
Shield

(20) Remove and discard the piston ring type seal
(Fig. 21).

CAUTION:
The
wheel
and
shaft assembly
is
bal­
anced
as a
unit.
If the
turbine blades
or
shaft
are

damaged,
the
complete assembly must
be
replaced.

(21) Remove and discard the outer retainer rings
(Fig. 22). (22) Remove and discard the turbocharger shaft
bearings (Fig. 22). (23) Remove and discard the inner snap rings (Fig.

22).
CLEANING
Use a stiff bristle nylon brush and solvent to clean
all parts. Do not use a wire brush on the compressor
wheel. Do not bead blast the parts. Remove the carbon build up from the housing with
a scraper and a 240 grit emery cloth.
Polish the bearing surfaces with crocus and kero­
sene or diesel fuel. After rinsing in clean solvent, use compressed air
to dry the parts.

INSPECTION
In addition to the inspection specified during disas­
sembly, inspect all parts after cleaning.

•
EXHAUST
SYSTEM
AND
INTAKE MANIFOLD
11 - 23

HEAT
SHIELD
OUTER RETAINER
RINGS

BREAKING,
HOUSING
J9111-18

Fig.
24 Turbine Shaft/Heat
Shield
to Bearing
Housing

INNER
RETAINING
RINGS
INNER
RETAINING RING

J9111-14

Fig.
22
Snap Rings
and Shaft Bearing Measure the shaft bearing diameter (Fig. 23). The
minimum diameter should be 10.97 mm (0.432 inch).

SHAFT BEARING DIAMETER Fig.
25
Beveled
Face of
Inner
Retainer
Ring

J911M6

OUTER
RETAINING RING
J9111-15

Fig.
23 Shaft Bearing Diameter

ASSEMBLE
The balance marks must be aligned to make sure
the wheel and shaft assembly is balanced. (1) Install the piston ring and lubricate the groove
with engine oil.
(2) Install the heat shield (Fig. 24).
(3) Clamp a socket in a soft jawed vice and posi­
tion the shaft in the socket. (4) Install the inner retainer rings. The beveled
face must be towards the bearing (Fig. 25).
(5) Lubricate the turbocharger bearing with engine
oil and install the bearings in the housing.
(6) Install the outer retainer ring. The beveled face
must be towards the bearings (Fig. 26).
(7) Assemble the turbine shaft and heat shield to
the bearing housing. Rotating the housing as you
press downward will assist in properly seating the
piston ring.
OUTER
RETAINING RING

J9111-17
Fig.
26
Beveled
Face of Outer Retainer
Ring

(8) Install the thrust collar. Align the balance
mark with the balance mark on the shaft. Mark the
top surface with a marker pen so alignment can be verified after installing the thrust bearing.
(9) Lubricate the thrust bearing with engine oil
and install it on the housing. Tighten the torx bolts
to 4.5 N»m (40 in. lbs.) torque.

11
- 24
EXHAUST
SYSTEM
AND
INTAKE
MANIFOLD

(10) Install the oil baffle. Check the balance mark
alignment. (11) Install the piston ring type seal on the oil
slinger (Fig. 27).
Fig.
27
Piston
Ring
Type
Seal

(12) Mark the top surface of the oil slinger line
with the balance mark.
(13) Lubricate the oil slinger with engine oil and
install it into the diffuser.
(14) Install the O-ring into the diffuser. (15) Install the diffuser. Align the balance marks
on the shaft and the oil slinger (Fig. 28).
Fig.
28
Align
Balance
Marks—Shaft and Oil
Slinger

(16) Align the balance mark and install the impel­
ler (Fig. 29). Be careful not to move the bearing
housing. (17) Do not allow the impeller to turn when in­
stalling the nut. The impeller nut and the shaft have
LEFT hand threads. Tighten the nut to 14 N-m (129
in. lbs.) torque.
(18) Install the bearing housing assembly into the
turbine housing (Fig. 30). (19) Align the scribe marks (Fig. 30).
(20) Apply anti-seize compound to the bolt threads. (21) Install the clamp plates, lock plates and bolts
(Fig. 31). Tighten the bolts to 11.3 N-m (100 in. lbs.)
torque.
Fig.
29
Align
Balance
Marks—Impeller

Fig.
30 Bearing
Housing
Assembly/Turbine
Housing
Fig.
31 Install
Clamp
Plates/Lock
Plates
(22) Install the lock plates and bolts into the
dif­

fuser (Fig. 32).
(23) After tightening the bolts to 5.7 N-m (50 in.
lbs.) torque, bend the lockplate tabs to lock the bolts.
Be sure the scribe marks are aligned.

•

EXHAUST
SYSTEM
AND
INTAKE MANIFOLD
11 - 25

Fig.
32 Diffuser and Lockpiate (24) Measure the end play (Fig. 33). For turbo­
charger with a serial number before 840638 the end
play should be 0.102-0.152 mm (0.004-0.006 inch).
For turbocharger with a serial number of 840638 and after the end play should be 0.026-0.076 mm
(0.001-

0.003 inch).
(25) Measure radial clearance of the shaft (Fig.

33).
The clearance should be 0.300-0.460 mm (0.012-
0.018 inch).

Fig.
33 End Play/Radial Clearance of Shaft
(26) Install the square cut O-ring.
(27) Be sure the scribe marks are aligned. Install
the compressor housing and V-Band clamp. Apply anti-seize compound to the V-Band bolt threads.
Tighten the clamp to 8 N-m (72 in. lbs.) torque. Tap against the clamp on 4 places around its circumfer­

ence.
Again tighten the clamp to 8 N-m (72 in. lbs.)
torque.

INSTALLATION
(1) Install a new gasket and apply anti-seize com­
pound to the mounting studs. (2) Install the turbocharger. Tighten the turbo­
charger mounting nuts to 32 N-m (24 ft. lbs.) torque. (3) Use a new gasket and connect the drain line.
Tighten the drain line connection bolts to 24 N-m (18
ft. lbs.) torque.
(4) New turbocharger must be pre-lubricated with
clean engine lubricating oil before start up. Pour 50-60 cc (2-3 ounces) of oil into supply fitting.

WARNING:
DO NOT USE
YOUR FINGER
TO
TURN
THE TURBINE WHEEL.

(5) Rotate the turbine wheel to allow oil to enter
the turbocharger.
(6) Install the oil supply line. Tighten the oil sup­
ply line fitting nut to 15 N-m (11 ft. lbs.) torque. (7) Position the Charge air cooler (intercooler) in­
let duct to the turbocharger. With the clamp in posi­
tion, tighten the clamp nut to 8 N-m (72 in. lbs.) torque.
(8) Position the air intake pipe and the exhaust
pipe onto the turbocharger. Tighten the clamps to 8 N-m (72 in. lbs.) torque.
(9) Connect the negative cable to the battery.
(10) Operate the engine and check for leaks.

CHARGE
AIR
COOLER (INTERCOOLER)
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 (intercooler) located in front of the radiator. From the charge air cooler (in­
tercooler) the air flows back into the intake manifold. The charge air cooler (intercooler) is a heat ex­
changer that uses air flow to dissipate heat from the
intake air. As the turbocharger increases air pres­

sure,
the air temperature increases. Lowering the in­
take air temperature increases engine efficiency and
power.
REMOVAL

WARNING:
IF THE
ENGINE
WAS
JUST TURNED OFF,
THE
INTAKE
AND
OUTLET
DUCTS
MAY BE
HOT.

(1) Remove the grille (refer to Group 23, Body for
the proper procedure).
(2) Remove the front support bracket (Fig. 34).
(3) If the vehicle is equipped with air conditioning,
remove the condenser as follows:
(a) Discharge the air conditioning system (refer
to Group 24, Heating and Air Conditioning for the
proper procedures).
(b) Remove the bolt from the sealing plate (Fig.

34).

(c) Remove the nuts holding the condenser to the
charge air cooler (intercooler) (Fig. 34). Lift the