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Removal - Turbocharger

WARNING: This page is about a different car, the 2006 Dodge Magnum, 2006 Dodge Charger, and 2006 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Removing/Installing Air Intake Tube (Air Cleaner To Turbo)
GC0039541Courtesy of DAIMLERCHRYSLER CORP.
WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOL. CARE SHOULD BE TAKEN WHEN WORKING NEAR THE TURBOCHARGER. THE TEMPERATURE OF THE TURBOCHARGER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME.
NOTE: THERE IS NO PROCEDURE FOR REPAIRING THE TURBOCHARGER. IF DAMAGE IS FOUND DURING INSPECTION, THE TURBOCHARGER MUST BE REPLACED.
  1. Disconnect negative battery cable.
  2. Remove the engine trim cover.
  3. Remove air intake tube (air cleaner to turbo) (1). See Fig 1.
  4. Remove engine cover front bracket (2).
  5. Remove air tube (turbo to cooler) (3).
  6. Remove the turbo heat shield (4).
    Fig 2: Removing/Installing Air Intake, Turbo, Exhaust System Components
    GC0039540Courtesy of DAIMLERCHRYSLER CORP.
  7. Remove the exhaust clamp (elbow to converter) (1). See Fig 2.
    Fig 3: Removing/Installing Turbo, Shields, Exhaust System, Support Brackets Components
    GC0039543Courtesy of DAIMLERCHRYSLER CORP.
  8. Remove the turbo front bracket retaining bolts (1). See Fig 3.
  9. Drain cooling system (Refer to STANDARD PROCEDURE ).
  10. Disconnect the downstream catalytic converter at the extension pipe.
  11. Disconnect the extension pipe to muffler.
  12. Disconnect O2 sensor wire connector.
  13. Reposition extension pipe and catalytic converter.
  14. Lower vehicle and disconnect catalytic converter to downstream catalytic converter clamp.
  15. Remove upstream catalytic converter.
  16. Disconnect transmission fill tube and trim cover bracket and set aside.
    Fig 4: Removing/Installing Air Intake, Turbo, Exhaust System Components
    GC0039540Courtesy of DAIMLERCHRYSLER CORP.
  17. Disconnect exhaust elbow at turbo (2). See Fig 4.
  18. Disconnect EGR tube at manifold to left cylinder head (3).
  19. Remove left and right exhaust manifold retaining bolts and gaskets (4).
    Fig 5: Removing/Installing Air Intake Tube (Air Cleaner To Turbo)
    GC0039541Courtesy of DAIMLERCHRYSLER CORP.
  20. Remove front turbo retaining bolts (1). See Fig 5.
  21. Remove turbo mount retaining bolts.
  22. Remove turbo.
  23. Disconnect turbo boost pressure servo connector (2).
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