Copyright by Goodheart-Willcox Co., Inc.
Chapter 16 Turbocharging and Supercharging Systems 335
Waste gate
diaphragm
Compressor
housing
Compressor
wheel
Center
housing
Waste gate
valve
Outlet elbow
Turbine housing
Turbine wheel
Figure 16-10. An exploded view of a turbocharger showing how the internal parts fit together. (Ford)
plugs, or a damaged catalytic converter. To check for
blockage, remove the return line at the turbocharger and
blow air back through the line. If you find blockage, it is
best to replace the line with a new one instead of trying to
remove the restriction.
When overhauling a turbocharger, it is very important
that you do nothing to upset the balance of the turbocharger
wheels. If you bend the turbo shaft loosening or even one
blade slightly, the turbocharger will be out of balance and
may self-destruct the first time it spins up to boost pressure.
When disassembling the turbocharger housings or
wheels, mark their position. Use a scratch awl to make
very small alignment marks. When loosening the wheel
nut, be careful not to bend the turbo shaft. It is best to use a
T-handle and socket to loosen the turbo shaft nuts without
side-loading the shaft.
Caution: Never use a hard metal object or
sandpaper to remove carbon deposits from
the turbo wheels. If you gouge or remove
metal, the wheel can vibrate and destroy the turbo.
Use only a soft wire brush and solvent to clean the
turbo wheels.
Installing a Turbocharger
Installing a turbocharger is basically the reverse of
removing it. When installing a turbo, you should:
Make sure the new turbo is the correct type.
Use new gaskets and seals.
Torque all fasteners to specifications.
Change the engine oil and flush oil lines before start-
ing engine, if needed.
Check oil supply pressure in the feed line to the turbo.
Check the waste gate for proper operation.
Waste Gate Service
An inoperative waste gate can cause either too much
or too little boost pressure. However, always check other
parts before diagnosing the waste gate. Check the knock
sensor and the ignition timing. Make sure the vacuum and
pressure lines are all connected properly.
Follow service manual instructions when testing a
waste gate. Figure 16-11 shows how to check the opera-
tion of a waste gate. If the waste gate is not functioning
properly, it must be replaced.
Waste gate removal is simple. Remove the fasteners.
Remove the lines and lift the unit off of the engine. Then,
simply install the new waste gate. Many manuals recom-
mend waste gate replacement rather than in-shop repairs.
Turbocharger Intercooler Service
Intercoolers are very dependable. However, they can
be damaged or can deteriorate from extended service.