TURBOCHARGER UNIT – Operations in case of replacement - Service Manual update

Service news 10.07.03

2.4 JTD 10V, 2.4 JTD 20V

TURBOCHARGER UNIT

Operations in case of replacement - Service Manual update

OPERATIONS IN NETWORK

In addition to the information in the Service Manual we are enclosing the operations to be carried out if the turbocharger is being replaced on account of:

A. Noise without seizing or turbocharger defective

B. Noise with seizing or presence of oil spillage at the intake and at the exhaust

• When replacing the turbocharger on account of noise without seizing or through defects, proceed with:. Replacing the connector (1 - Fig. 1) for the turbocharger (3) lubrication pipe (2); the connector is located on the crankcase and contains a small filter for the oil.
• Replacing the connector (1 - Fig. 1) for the turbocharger (3) lubrication pipe (2); the connector is located on the crankcase and contains a small filter for the oil.

• When replacing the turbocharger on account of noise with seizing or the presence of oil spillages at the intake and at the exhaust, proceed with:. Replacing the connector (1 - Fig. 1) for the turbocharger (3) lubrication pipe (2); the connector is located on the crankcase and contains a small filter for the oil.·. Internal washing with pressurized fluid of the oil supply pipe between the crankcase and the turbocharger.·. Thorough washing of the intercooler and the entire section of the intake downstream of the turbocharger
• Replacing the connector (1 - Fig. 1) for the turbocharger (3) lubrication pipe (2); the connector is located on the crankcase and contains a small filter for the oil.·
• Internal washing with pressurized fluid of the oil supply pipe between the crankcase and the turbocharger.·
• Thorough washing of the intercooler and the entire section of the intake downstream of the turbocharger

The washing is carried out using a "heptane type" degreasing fluid if foreign bodies are found (shavings, pieces of plastic/metal etc.) notify Te.Se.O. immediately.

• Check the condition of the intake system upstream of the turbocharger and, if necessary clean and/or wash it.

When using chemicals, closely follow the safety instructions given on the safety sheet which the supplier must give to the user (in Italy, in accordance with Legislative Decrees 52/97 and 285/98 and later modifications and inclusions).

• Draining and (where possible) blowing through the oil contained in the precatalyzer, the catalyzer and the entire exhaust system, dismantled previously and dismantled into its various components

It should be remembered that the draining and blowing through operations should be carried out safely with a suitable suction system and/or sealed washing and blowing system. At the end of the refitting procedure, gradually warm up the engine and the entire exhaust system in order to be able to eliminate as much of the oil as possible without burning the catalyzer and thereby get rid of any light blue fumes before returning the vehicle to the Customer.

Fig. 1

Key

• connector (filler)
• turbocharger bearing lubrication pipe (from the turbocharger to the crankcase)
• turbocharger

Each time the turbocharger is returned (for example to Genco-Gemca) the bolt shown by the arrow in Fig. 1 must also be returned