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Turbocharger System: Turbocharger: Installation: Installation

CAUTION:

The oil supply and return lines MUST be replaced whenever the lines are loosened or removed.

Fig 1: Manifold/Turbocharger Nuts
GC0153796Courtesy of CHRYSLER GROUP, LLC
  1. With the manifold removed, invert the manifold and turbocharger.
  2. Install a new  gasket onto the manifold/turbocharger mating surface.
  3. Set the manifold onto the turbocharger studs and install four new  nuts (1) by hand.
  4. Tighten the four nuts to 24 N.m (18 ft. lbs.).
  5. After the nuts are tightened to 24 N.m (18 ft. lbs.) once, repeat the step to be sure that all nuts are at the proper torque.
    NOTE:

    Replace any stud that loosens during removal. If a stud is to be replaced, tighten the new stud to 11 N.m (97 in. lbs.). Age of the vehicle and environment impact how many of the studs come out. Any that stay in the head also need to be checked for the 11 N-m (97 in. lbs.).

    Fig 2: Exhaust Manifold Fastener Tightening Sequence
    GC0153801Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The turbocharger has been removed for clarity.

    NOTE:

    When screwing the studs into the head, install them dry. Do not apply any lubricants, adhesives, sealants or the like to the threads. The new studs have a locking adhesive impregnated into the threads.

  6. Install new manifold studs. Tighten the studs to 11 N.m (97 in. lbs.).
  7. Install a new  manifold gasket/shield assembly.
  8. Set the manifold and turbocharger assembly onto the cylinder head studs.
  9. Install the nine exhaust manifold washers and new  nuts (1).
  10. 1) Tighten to 15 N.m (133 in. lbs.) in order from 1 to 9.
  11. 2) Retighten to 15 N.m (133 in. lbs.) in order from 1 to 4 only  .
  12. 3) Add additional 30 degrees (one 1/8 of a turn) of clockwise rotation to all  in order from 1 to 9.
    Fig 3: Converter/Turbo Gasket Ring
    GC0153789Courtesy of CHRYSLER GROUP, LLC
  13. Position the exhaust manifold shield and install the two bolts and one new  nut.
  14. Tighten the shield bolts to 9 N.m (80 in. lbs.).
    CAUTION:

    Band clamps should never be tightened such that the two sides of the clamps are bottomed out against the hourglass shaped center block. Once this occurs, the clamp has lost clamping force and must be replaced.

  15. Install the new  converter to turbo seal ring (1).
    Fig 4: Turbocharger, Catalytic Converter Clamp & Catalytic Converter Assembly
    GC0153788Courtesy of CHRYSLER GROUP, LLC
  16. Install the catalytic converter assembly (3).
  17. Install the catalytic converter v-clamp (2) at the turbocharger (1).
  18. Tighten clamp to 8 N.m (71 in. lb).
  19. Connect the O2 sensor connector.
    Fig 5: Catalytic Converter, Support Mount & Bolts
    GC0153601Courtesy of CHRYSLER GROUP, LLC
  20. Install the catalytic converter lower support bracket (2).
  21. Install and tighten the bracket bolts (3) to 56 N.m (41 ft. lbs.).
  22. Install a new converter to pipe gasket.
  23. Install the front exhaust pipe.
  24. Install the nuts that secure the cross under pipe to the catalytic converter.
  25. Tighten the front exhaust pipe nuts to 56 N.m (41 ft. lbs.).
    Fig 6: Front Exhaust Pipe Support Bolt & Flange Nuts
    GC0153120Courtesy of CHRYSLER GROUP, LLC
  26. Install the front exhaust pipe support bolt (2). Tighten to 56 N.m (41 ft. lbs.).
  27. Install the exhaust flange nuts (1). Tighten to 69 N.m (51 ft. lbs.).
    Fig 7: Turbocharger Pressure Sensor Hose, Actuator Pump, Oil And Coolant Supply Line Banjo Bolt, Lower Oil Return Line & Turbocharger Surge Valve Connector
    GC0153794Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Banjo bolts and banjo bolt gaskets must be replaced during assembly. 

    NOTE:

    The oil supply and return lines must be replaced during assembly or ANY TIME the fittings are loosened to prevent turbine bearing failure due to debris. 

  28. Connect the wastegate supply hose to the actuator pump (2).
  29. Connect the turbocharger pressure sensor hose (1).
  30. Install the coolant return line with new washers  located on the rear side of the turbocharger. Tighten to 38 N.m (28 ft. lbs.).
  31. Install the coolant supply banjo bolt (4) and new  washers. Tighten to 38 N.m (28 ft. lbs.).
  32. Install the new  oil supply line, banjo bolts (3) and washers. Tighten to 30 N.m (22 ft. lbs.).
  33. Install the lower new  oil return line (5) and new upper gasket. Tighten the bolt to 14 N.m (124 in. lbs.).
  34. Install the previously removed surge valve and tighten the bolts to 9 N.m (80 in. lbs.)
  35. Connect the turbocharger surge valve connector (6).
    Fig 8: Charge Air Cooler Supply Hose, Heat Shield, Nuts & Bolts
    GC0153600Courtesy of CHRYSLER GROUP, LLC
  36. Install the Charge Air Cooler (CAC) supply hose (5) to the turbocharger.
  37. Install the CAC hose clamp and tighten.
  38. Install the catalytic converter heat shield (3). Install the bolts and new  nuts. Tighten the nuts and bolts to 8 N.m (71 in. lbs.).
    Fig 9: Upper Heat Shield Bolts & Nuts
    GC0153792Courtesy of CHRYSLER GROUP, LLC
  39. Install the upper heat shield. Install the three bolts and the two new  nuts. Tighten the bolts and the nuts to 9 N.m (80 in. lbs.). Care must be taken when tightening the shield bolts. If torque value is not correct, noise will occur. 
  40. Connect the upstream and downstream oxygen sensor connectors.
    Fig 10: Turbocharger Bracket & Fasteners
    GC0153805Courtesy of CHRYSLER GROUP, LLC
  41. Install the turbocharger bracket (2), bolts (1) and new  nut (3).
  42. Tighten the bolts and nut to 25 N.m (18 ft. lbs.).
    Fig 11: Front Cooling Module Assembly & Fasteners
    GC0153119Courtesy of CHRYSLER GROUP, LLC
  43. Position the Front End Module onto the front of the vehicle.
  44. Install the front end module assembly (4) with four bolts (1), eight bolts and washers (2) and eight bolts and washers (3). Tighten the eight bolts (2) to 45 N.m (33 ft. lbs.). Tighten the four bolts (1) to 24 N.m (18 ft. lbs.). Tighten the eight bolts (3) to 45 N.m (33 ft. lbs.).
    Fig 12: Throttle Body Inlet Hose, Turbocharger Outlet Hose & Cooling Fan
    GC0153790Courtesy of CHRYSLER GROUP, LLC
  45. Connect the throttle body inlet hose (1) and turbocharger outlet hose (2) at the lower quick disconnects located behind the cooling fan (3).
    Fig 13: Wire Harness Retainer
    GC0103128Courtesy of CHRYSLER GROUP, LLC
  46. Engage the block heater wire harness retainer (1) at the upper core support.
    Fig 14: Horn & Connector
    GC0153791Courtesy of CHRYSLER GROUP, LLC
  47. Connect the wire harness connector (1) to the horn (2).
  48. Engage the wire harness connector to the bumper reinforcement.
    Fig 15: Front Impact Sensor & Connector
    GC0153793Courtesy of CHRYSLER GROUP, LLC
  49. Connect the wire harness connector (2) to the right and left front impact sensors (1).
    Fig 16: Latch Cable
    GC0084616Courtesy of CHRYSLER GROUP, LLC
  50. Press down the latch release (3) and install the hood latch cable (2) to the latch.
    Fig 17: A/C Liquid Line, A/C Discharge Line, A/C Condenser Tapping Block & Bolt
    GC0152540Courtesy of CHRYSLER GROUP, LLC
  51. Engage the A/C liquid line (1) to the A/C discharge line (2) and connect the lines to the A/C condenser tapping block (3) using new dual plain seals lubricated with clean refrigerant oil. Install the retaining bolt (4) and tighten to 14 N.m (10 ft. lbs.).
    Fig 18: Engine Cooling Fan, Connector & Fasteners
    GC0152367Courtesy of CHRYSLER GROUP, LLC
  52. Connect the cooling fan electrical connector (3).
  53. Install the upper and lower radiator hoses and clamps. Tighten the clamps.
  54. Recharge the AC system to specifications.
    Fig 19: Cooling Fan Resistor & Fan Assembly
    GC0152401Courtesy of CHRYSLER GROUP, LLC
  55. Connect the electrical connector to the cooling fan resistor (1).
    Fig 20: Left Headlamp & Fasteners
    GC0153009Courtesy of CHRYSLER GROUP, LLC
  56. Install the right and left headlamp units (2).
  57. Install the fascia assembly. Refer to FASCIA, FRONT, INSTALLATION .
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