Turbocharger - Component Availability/Replacement

84mitsubishi02 SUBJECT:

STARION TURBOCHARGER COMPONENT REPLACEMENT PROCEDURES
NO. STB-84-010

DATE May 1984

MODEL 1983, 1984 Starion
INTRODUCTION

Turbocharger components, previously not available as individual replacement parts, may now be ordered individually. This bulletin is issued to describe the disassembly, inspection and assembly procedures. Part numbers may be found in Parts Bulletin MSPP006184.

DIAGNOSING THE NEED FOR TURBO COMPONENT REPLACEMENT

Lack of power, low boost pressure, loud or unusual noise ore early waming signals of turbo wear. When a customer complains of turbo noise alone, the judgment of the service manager is necessary to determine whether inspection and/or replacement of internal parts is needed. All turbochargers make a siren-like sound which in itself is not an indication of wear.

Inspection of the oil pipe can give some valuable clues as to what may be found inside the turbo. If the oil pipe is blocked with sludge or deposits, chances are the turbocharger bearing has received insufficient lubrication and may have become worn.

Visual inspection of the outside of the turbocharger assembly reveals any obvious discoloration of metal parts which would indicate excessive heat build-up.

Oil pipe blockage, excessive noise, or evidence of overheating or seizure require disassembly and inspection.

If the turbo oil feed pipe on the car is a type that attaches directly to the exhaust manifold, replace it with a new pipe and bracket which bolts to the exhaust manifold flange, as described in STB-84-14-011.

SAFETY REMINDER

The turbocharger operates at high temperatures and retains heat long after the engine is stopped. When working on the turbocharger, take suitable precautions against skin contact with hot surfaces!

Figure 1:

DISASSEMBLY PROCEDURE

1. Disconnect the air intake hose from the compressor inlet.
2. Disconnect the air intake pipe from the compressor outlet and the injector air pipe. Set the air intake pipe aside.
3. Remove the five heat insulator attaching bolts and move the insulator out of the way carefully to avoid damaging the oxygen sensor or its lead.
4. Disconnect the oil feed pipe from the oil pipe joint, and remove the oil pipe joint from the turbo.
5. Remove the hairpin clip from the waste gate valve lever and disconnect the waste gate actuating rod from the lever.
6. Disconnect the oll return hose from the oil return pipe.
7. Remove the coupling. Joining the compressor cover assembly and turbine housing.

NOTE:
Support the compressor cover assembly to keep from dropping it.

8. Pull the compressor cover and cartridge containIng the turbine wheels straight out from the turbine housing to avoid damaging the fragile turbine blades. Set the assembly carefully on the workbench.
9. Disconnect the oil pipe from the oil filter housing and exhaust manifold and remove for inspection or replacement.

INSTRUCTION OF COMPONENTS

1. Inspect the cast iron turbine housing for damage, cracks, or evidence of contact between the turbine blades and the housing. Manually open and close the waste gate valve to make sure it operates freely. If there is no damage or wear on the turbine housing and the waste gate valve operaflon appears normal, there is no need to remove the turbine housing from the vehicle. If the housing is to be replaced, remove it from the engine.
2. Inspect the oil pipe ends for evidence of cokelike deposits. If present, replace the oil pipe. If the pipe is the type that attaches directly to the exhaust manifold, remove it and replace it with a new pipe and bracket. See STB-84-14-014.
3. Inspect the oil pipe joint to make sure the oil passage is clear. Use a stiff wire or similar tool to clean out the passage, if necessary.
4. Clamp the compressor cover in a brass-jawed vise. Remove the oil return pipe and waste gate valve actuator.
5. Remove the snap ring from the compressor cover.
6. Tap the cartridge casting with a softface hammer to unseat the O-ring, and withdraw the cartridge from the cover, taking care not to damage the turbine blades.
7. Inspect the oil passage in the cartridge for signs of deposits or blockage. Inspect the turbine wheels for wear, damage, bent or broken blades. Spin the turbine; it should turn freely. Move the turbine shaft from side to side and end to end to determine if worn.

NOTE:
A certain amount of side to side clearance is normal. The space between the bearing and shaft is needed to allow oil under pressure to flow freely when the turbine is running. Normal end play is much less than side play. If visual inspection determines that the oil passage in the cartridge contains sludge or coke deposits, or if the turbine blades are broken, bent, damaged, or worn, or if the turbine shaft does not spin freely or appears worn, replace the cartridge assembly.

8. Clean the inlet section of the compressor cover with a rag. Inspect it for signs of contact with the compressor turbine. If worn, replace it.
9. Leak-test the waste gate valve actuator with a hand pump as shown in Figure 9. Replace the actuator if leakage indicates a ruptured diaphragm. Check the rod to see that it is not bent or binding so as to require replacement.
10. Inspect the oil return pipe to make sure it is clear. If blocked, clean it out.

REASSEMBLY PROCEDURE

1. Replace the O-ring in the cartridge with a new one. Lubricate the O-ring with a thin film of motor oil for reassembly.
2. With the compressor cover clamped in a brassjawed vise, line up the oil inlet hole in the top side of the cartridge with the casting mold parting line mark on the cover; push into place and secure with the snap ring.

NOTE:
Be sure the beveled side of the snap ring is up.

3. Assemble the waste gate valve actuator to the compressor cover.
4. Assemble the oil return pipe to the cartridge using a new gasket. Torque the attaching bolts to 8-10 N-m (6-7 ft.lbs.)
5. Assemble the oil feed pipe to the engine as described in STB-84-14-011.
6. If the turbine housing has been removed, install it at this time, using new gaskets (15, Fig. 1) if necessary. Torque the nuts to 49-68 N-m (37-50 ft.lbs.).
7. Assemble the compressor cover and cartridge assembly to the turbine housing with the oil hole at the top. Insert the oil return pipe into the oil return hose. Install the coupling with its bolt and nut, but leave the nut loose.
8. Pour a small amount of clean motor oil into the oil feed hole to provide initial lubrication to the turbine bearing.
9. Install the oil pipe joint and torque to 22-26 N-m (16-20 ft.lbs.).
10. Connect the oil pipe to the oil pipe joint. Rotate the compressor cover if necessary, to get the nut started. Torque the nut to 16-23 N-m (12-17 ft.lbs.).
11. Install the air intake pipe.
12. Adjust the length of the waste gate valve actuator rod, if necessary so that when the waste gate valve is shut tight (lever held straight up), the rod is just long enough to slip onto the lever pin. Install the hairpin clip.
13. Tighten the coupling nut to 10-11 N-m (7-8 lbs.).
14. Assemble the heat insulator, and connect the air Intake hose to the compressor Inlet.
15. Start the engine and allow it to idle a minute, thereby providing an adequate flow of oil into the turbo bearing. Check for oil and air leaks.

CAUTION:
Do not race engine until full oil pressure has been reached.

CONSIDERATION

Labor operation codes and time allowances are as follows:

Turbo Assembly, Replace
09-46-01-01 0.9h

Turbocharger - Remove, Rebuild and Reinstall*
09-46-01-02 1.3h

Oil Pipe, Replace
09-46-04-01 0.3h

* NOTE: This operation number cannot be used with 09-46-01-01 as it includes the time allowance for removal and re-installatlon of the turbo assembly.