Turbocharger Cleaning Port
INSTALL A TURBOCHARGER CLEANING PORT
WARNING: At no time should a combustible cleaner be used. To introduce a combustible cleaner to the engine and/or exhaust aftertreatment system may cause damage to those systems and possible personal injury.
1. At the filter housing cover, disconnect the Mass Air Flow (MAF) and the Inlet Air Temperature/Pressure (TBAP) sensors electrical connectors from the engine harness.
2. Remove the air filter housing cover (1) and fresh air tube together as as assembly.
3. With the turbocharger actuator electrical connector connected, turn the vehicle ignition switch to "ON/RUN" position. DO NOT start the engine.
4. Disconnect the turbocharger actuator electrical connector (1) from the engine harness.
5. Turn the vehicle ignition switch to the "OFF" position.
6. Disconnect and isolate negative battery cables on each battery.
CAUTION: Performing the above steps now will become very important later in this procedure. The above steps should not be overlooked. The above steps will insure that the nozzle ring inside the turbocharger is moved so that it will not come in contact with the drill bit or tap. Failure to perform the above steps may damage the turbocharger mechanism.
7. Located the Closed Crankcase Ventilation (CCV) tube hold down cap screw on the steel section of the CCV tube. Remove the CCV tube hold down cap screw.
8. Rotate the CCV tube upward and out of the way of the turbocharger.
9. Located the turbocharger speed sensor that is mounted on top of the center section (bearing housing) of the turbocharger housing.
NOTE: Clean the area of any dirt and/or debris that may be around the turbocharger speed sensor prior to removal.
10. Remove the turbocharger speed sensor attaching bolt (1). The bolt will be used later to hold in place the drill/tap guide of the #10143 turbocharger drill/tap kit.
11. Remove the turbocharger speed sensor (2). Verify that the speed sensor o-ring remains with the speed sensor and does not remain in the turbocharger center section/bearing housing.
12. Using the #10143 turbocharger drill/tap kit, install the drill/tap guide (1) into the turbocharger center section/bearing housing. Secure the drill/tap guide (1) in place with the previously removed turbocharger speed sensor attaching bolt. Tighten the bolt to 10 Nm (89 in lbs).
NOTE: There are two different size guide bushing that come with the #10143 turbocharger drill/tap kit. The guide bushing with the smaller inner diameter center bore is used for guiding the drill bit. The guide bushing with the larger inner diameter center bore is used to guide the tap.
13. Using the #10143 turbocharger drill/tap kit, install and secure the guide bushing with the small diameter bore hole (drill bit guide bushing) into the drill/tap guide bore.
NOTE: Only use special tool drill bit and stop (#10143-4) and tap (#10143-5) supplied in the Turbocharger Drill/Tap Kit #10143 to perform this Repair Procedure. ALWAYS check the drill stop to see if it is set correctly. It should be 42 mm (1 5/8 in.) from drill bit tip to bottom surface of the stop. VERIFY that the drill stop is set to the correct depth. VERIFY that the stop set screws are fully tightened. DO NOT over drill the hole.
14. Obtain a shop vacuum with a crevice attachment end to collect drill bit filings. Make certain that the crevice tool is held as close as possible to the drill tip when drilling, and to the tap when tapping the drilled hole. A small amount of filings that may enter into the drilled hole is acceptable.
NOTE: DO NOT use any machining oil or other lubrication oil during the drilling and tapping operation. Use of machining oil or other lubricating oil may increase the number of drill and tap shavings introduced into the turbocharger, potentially leading to turbocharger mechanism failure.
15. Using a drill on SLOW speed and the shop vacuum to collect filings, drill a hole through the turbocharger center housing casting to the correct depth. Continue to drill until the drill stop just makes contact with the turbocharger housing.
16. Remove the drill bit from the drill/tap guide. Remove the drill guide bushing from the drill/tap guide. First, vacuum any excess metal filings. Next, using a pencil magnet with a magnetic tip smaller than the drilled hole, insert the magnet through the drilled hole and remove shavings as possible. DO NOT use the magnet during the process of drilling and taping as this would cause the drill/tap fixture and the turbocharger housing to become magnetized.
17. Using the #10143 turbocharger drill/tap kit, install and secure the guide bushing with the larger diameter guide bore (tap guide bushing) into the drill/tap guide bore.
NOTE: Only use special tool drill bit and stop (#10143-4) and tap (#10143-5) supplied in the Turbocharger Drill/Tap Kit #10143 to perform this Repair Procedure. ALWAYS check the drill stop to see if it is set correctly. It should be 42 mm (1 5/8 in.) from drill bit tip to bottom surface of the stop. VERIFY that the drill stop is set to the correct depth. VERIFY that the stop set screws are fully tightened. DO NOT over drill the hole.
18. Using the #10143 turbocharger drill/tap kit, install the tap into the tap bushing bore of the drill/tap guide.
19. Using the #10143 turbocharger drill/tap kit, install the tap handle to the drive end of the tap. If additional clearance is desired, install the female end of a 3 inch or 6 inch long 1/4 inch drive socket extension to the tap and then install the male end of the 1/4 inch extension to the tap handle.
NOTE: DO NOT use any machining oil or other lubrication oil during the drilling and tapping operation. Use of machining oil or other lubricating oil may increase the number of drill and tap shavings introduced into the turbocharger, potentially leading to turbocharger mechanism failure.
20. Using the tap and tap handle from the #10143 turbocharger drill/tap kit in conjunction with the shop vacuum to collect filings, tap the previously drilled hole made in the turbocharger center housing casting approximately 11 1/2 turns. This should be just about when turbocharger housing just touches the bottom of the tap stop. DO NOT OVER TAP THE HOLE.
21. Remove the tap from the drill/tap guide. Remove the tap bushing from the drill/tap guide. First, vacuum any excess metal filings. Next, using a pencil magnet with a magnetic tip smaller than the drilled hole, insert the magnet through the drilled hole and remove as many shavings as possible. DO NOT use the magnet during the process of drilling and taping as this would cause the drill/tap fixture and the turbocharger housing to become magnetized.
22. Remove the drill/tap guide from the turbocharger center housing. First, vacuum any excess metal filings. Next, using a pencil magnet with a magnetic tip smaller than the drilled hole, insert the magnet through the drilled hole and remove as many shavings as possible.
23. Install the turbocharger speed sensor and attaching bolt to the turbocharger center housing. Tighten to attaching bolt to 10 Nm (89 in lbs).
24. Install the stainless steel Mopar turbocharger cleaning port plug into the cleaning port of the turbocharger. Tighten the plug to 10 Nm (89 in lbs). Verify correct fit before proceding.
NOTE: The use of the proper Mopar Turbocharger Cleaning Port plug is critical. Use of an unapproved plug of different material type and/or thread may cause damage to the turbocharger.
25. Connect the engine harness connector to the turbocharger actuator connector.
26. Rotate the CCV tube into position and install the CCV tube cap screw. Tighten the cap screw to 10 Nm (89 in lbs).
27. Install the air filter housing cover and fresh air tube hose. Tighten the fresh air hose clamp to 4 Nm (35 in lbs). Verify that there is a good seal at each end of the air tube hose.
28. Connect the engine harness connectors to the MAF and the inlet air temperature/pressure (TBAP) sensor connectors.
29. Connect the negative battery cable to each battery.
30. Start the vehicle engine and verify correct engine operation.
31. Turn off vehicle engine. Verify that the ignition switch is in the "OFF" position.