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Removal-Gas Engines

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Fig 1: Clean Air Hose - 2.4L Turbo
GC0019347Courtesy of CHRYSLER LLC
1 - CLEAN AIR HOSE
2 - TURBOCHARGER
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.
  1. Disconnect negative battery cable.
  2. Drain cooling system. Refer to STANDARD PROCEDURE .
  3. Remove air cleaner housing and lid. Refer to HOUSING-AIR CLEANER .
  4. Disconnect clean air hose (1) from turbocharger (2).
    Fig 2: Charge Air Cooler Hoses
    GC0019344Courtesy of CHRYSLER LLC
  5. Disconnect throttle and speed control cables at throttle body.
  6. 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
  7. Disconnect air inlet hose at throttle body (1).
    Fig 3: Support Bracket
    GC0019345Courtesy of CHRYSLER LLC
  8. Disconnect vacuum hoses at throttle body and upper intake manifold.
  9. Remove upper intake manifold support bracket (2).
    Fig 4: Turbocharger Lines & Hoses
    GC0019349Courtesy of CHRYSLER LLC
  10. Remove upper intake manifold. Refer to MANIFOLD-INTAKE .
    CAUTION: Cover lower intake manifold opening with suitable cover to prevent any foreign objects from entering.
  11. Disconnect oil supply line (1) at turbocharger.
  12. Remove coolant return line (2).
    Fig 5: Converter To Exhaust Manifold Connection - 2.4L Turbo
    GC0019346Courtesy of CHRYSLER LLC
    1 - FLAG NUT
    2 - GASKET
    3 - NUT
    4 - BOLT
    5 - CATALYTIC CONVERTER
  13. Disconnect vacuum hoses from turbocharger.
  14. Raise vehicle on hoist.
  15. Disconnect muffler ground strap. Remove muffler. See REMOVAL .
  16. Disconnect downstream oxygen sensor.
  17. Remove fasteners (3 and 4) securing catalytic converter (5) to exhaust manifold.
  18. Remove catalytic converter and intermediate pipe as an assembly.
    Fig 6: Charge Air Cooler Hose
    GC0019348Courtesy of CHRYSLER LLC
    1 - CHARGE AIR COOLER
    2 - HOSE - TURBOCHARGER TO CHARGE AIR COOLER
    3 - NUT
  19. Remove turbocharger to charge air cooler hose assembly (2).
    Fig 7: Turbocharger Brackets And Heat Shields
    GC0019350Courtesy of CHRYSLER LLC
  20. Remove turbocharger lower heat shield (1).
  21. Remove turbocharger elbow support bracket (4).
  22. Remove turbocharger support bracket (2).
  23. Remove turbocharger elbow (3).
  24. Remove lower exhaust manifold fasteners that are accessible while vehicle is on hoist.
  25. Lower vehicle.
  26. Remove upper exhaust manifold fasteners.
  27. Remove turbocharger/exhaust manifold assembly from above/between the engine and cowl panel.
  28. Remove and discard exhaust manifold gasket.
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