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Gas Engines

CAUTION: If turbocharger is replaced due to a bearing failure, replacement of the oil pressure feed line is required. Oil return tube should be cleaned also.
NOTE: The turbocharger and exhaust manifold are serviced as an assembly. Do Not attempt to remove the turbocharger from the exhaust manifold. Exhaust leaks will result. It is recommended that the turbocharger elbow be replaced along with the turbocharger/exhaust manifold assembly.
Fig 1: Exhaust Manifold Tightening Sequence
GC0019354Courtesy of DAIMLERCHRYSLER CORP.
  1. Clean gasket sealing surfaces. Replace exhaust manifold gasket. DO NOT APPLY SEALER TO GASKET. 
    NOTE: Stainless steel layer of exhaust manifold gasket goes against cylinder head, graphite layer of gasket goes against manifold surface.
  2. Turbocharger/exhaust manifold assembly is installed from above/between the engine and cowl panel.
  3. Position turbocharger/exhaust manifold assembly in place. Gradually tighten fasteners, starting at center and progressing outward in both directions to 28 N.m (250 in. lbs.). Raise and lower vehicle for fastener access as necessary. Repeat tightening procedure until all fasteners are at specified torque.
  4. Install turbocharger elbow. Torque fasteners to 28 N.m (250 in. lbs.).
  5. Install turbocharger upper heat shield. Torque fasteners to 28 N.m (250 in. lbs.).
  6. Install turbocharger coolant supply line. Install NEW   washers. Torque banjo fitting bolt to 37 N.m (27 ft. lbs.). Torque flared fitting to 31 N.m (23 ft. lbs.).
  7. Replace oil return tube gasket. Install oil return tube. Torque fasteners to 12 N.m (105 in. lbs.). Make sure heat shield for oil return line is properly installed.
  8. Install turbocharger support bracket. Torque M8 fasteners to 28 N.m (250 in. lbs.) and M10 fasteners to 54 N.m (40 ft. lbs.).
  9. Install turbocharger elbow support bracket.
  10. Install turbocharger to charge air cooler hose assembly.
  11. Install catalytic converter and intermediate pipe as an assembly.
  12. Install fasteners securing catalytic converter to exhaust manifold. Torque fasteners to 28 N.m (250 in. lbs.).
    Fig 2: Banjo Bolt and Washers
    GC0019355Courtesy of DAIMLERCHRYSLER CORP.
    1 - BANJO BOLT
    2 - WASHERS
  13. Install muffler. Connect muffler ground strap. (Refer to EXHAUST SYSTEM/MUFFLER - INSTALLATION) .
  14. Connect downstream oxygen sensor.
  15. Lower vehicle.
  16. Connect vacuum hoses to turbocharger.
  17. Install coolant return line. Install NEW   washers (2). See Fig 2. Torque banjo fitting bolt to 37 N.m (27 ft. lbs.).
  18. Connect oil supply line at turbocharger. Torque flared fitting to 31 N.m (23 ft. lbs.).
    NOTE: The lower heat shield tabs must over lap the upper heat shield to prevent fatiguing and premature failure of the union.
  19. Install turbocharger lower heat shield. Torque fasteners to 28 N.m (250 in. lbs.).
  20. Install upper intake manifold:
  21. Install upper intake manifold support bracket.
  22. Connect vacuum hoses at throttle body and upper intake manifold.
  23. Connect air inlet hose at throttle body.
  24. Connect electrical connectors to the following components:
    1. Inlet Air Temperature (IAT) Sensor
    2. MAP Sensor
    3. IAC Motor
    4. Throttle Position Sensor
    5. Ignition Coil Capacitor
    6. Upstream Oxygen Sensor
  25. Connect throttle and speed control cables at throttle body.
  26. Connect clean air hose to turbocharger.
  27. Install air cleaner housing and lid .
  28. Fill cooling system, (Refer to COOLING/ENGINE/COOLANT - STANDARD PROCEDURE) .
  29. Change oil and filter.
  30. Connect negative battery cable.
  31. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
  32. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.
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