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: Clean Air Hose - 2.4L Turbo

Courtesy of DAIMLERCHRYSLER CORP.

1 - CLEAN AIR HOSE

2 - TURBOCHARGER

Disconnect negative battery cable.
Drain cooling system, (Refer to COOLING/ENGINE/COOLANT - STANDARD PROCEDURE) .
Remove air cleaner housing and lid
- For 1.6L, (Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL) .
- For 2.4L, (Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL) .

Disconnect clean air hose (1) from turbocharger (2). See Fig 1.

Fig 2: Charge Air Cooler Hoses

Courtesy of DAIMLERCHRYSLER CORP.

1 - HOSE - CHARGE AIR COOLER TO THROTTLE BODY

2 - CHARGE AIR COOLER

3 - HOSE - TURBOCHARGER TO CHARGE AIR COOLER

Disconnect throttle and speed control cables at throttle body.
Disconnect electrical connectors from 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
Disconnect air inlet hose at throttle body (1). See Fig 2.

Fig 3: Support Bracket
Courtesy of DAIMLERCHRYSLER CORP.

1 - FASTENERS

2 - UPPER INTAKE MANIFOLD SUPPORT BRACKET
Disconnect vacuum hoses at throttle body and upper intake manifold.

Remove upper intake manifold support bracket (2). See Fig 3.

Fig 4: Turbocharger Lines and Hoses

Courtesy of DAIMLERCHRYSLER CORP.

1 - OIL SUPPLY LINE

2 - COOLANT RETURN LINE

3 - COOLANT SUPPLY LINE

4 - OIL RETURN TUBE

Remove upper intake manifold
- For 1.6L, (Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - REMOVAL) .
- For 2.4L, (Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - REMOVAL) .
CAUTION: Cover lower intake manifold opening with suitable cover to prevent any foreign objects from entering.
Disconnect oil supply line (1) at turbocharger. See Fig 4.

Remove coolant return line (2).

Fig 5: Converter to Exhaust Manifold Connection - 2.4L Turbo

Courtesy of DAIMLERCHRYSLER CORP.

1 - FLAG NUT

2 - GASKET

3 - NUT

4 - BOLT

5 - CATALYTIC CONVERTER

Disconnect vacuum hoses from turbocharger.
Raise vehicle on hoist.
Disconnect muffler ground strap. Remove muffler (Refer to EXHAUST SYSTEM/MUFFLER - REMOVAL) .
Disconnect downstream oxygen sensor.
Remove fasteners (3, 4) securing catalytic converter (5) to exhaust manifold. See Fig 5.

Remove catalytic converter and intermediate pipe as an assembly.

Fig 6: Charge Air Cooler Hose

Courtesy of DAIMLERCHRYSLER CORP.

1 - CHARGE AIR COOLER

2 - HOSE - TURBOCHARGER TO CHARGE AIR COOLER

3 - NUT

Remove turbocharger to charge air cooler hose assembly (2). See Fig 6.

Fig 7: Turbocharger Brackets and Heat Shields

Courtesy of DAIMLERCHRYSLER CORP.

1 - UPPER/LOWER HEAT SHIELDS

2 - TURBOCHARGER SUPPORT BRACKET

3 - ELBOW

4 - ELBOW SUPPORT BRACKET

Remove turbocharger lower heat shield (1). See Fig 7.
Remove turbocharger elbow support bracket (4).
Remove turbocharger support bracket (2).
Remove turbocharger elbow (3).
Remove lower exhaust manifold fasteners that are accessible while vehicle is on hoist.
Lower vehicle.
Remove upper exhaust manifold fasteners.
Remove turbocharger/exhaust manifold assembly from above/between the engine and cowl panel.
Remove and discard exhaust manifold gasket.