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Home >> Fiat >> 2015 >> 500 Pop, Standard Trans >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 12 (1.4L 16-Valve Turbo Engine (Service Information) 500) >> Turbocharger System >> Turbocharger >> Removal >> Removal

Turbocharger System: Turbocharger: Removal: Removal

WARNING: This page is about a different variant/trim than selected.
  1. Disconnect and isolate the negative battery cable.
  2. Remove the front fascia. Refer to FASCIA, FRONT, REMOVAL .
    Fig 1: Left Headlamp & Fasteners
    GC0153009Courtesy of CHRYSLER GROUP, LLC
  3. Remove the right and left headlamp units (2).
    Fig 2: Cooling Fan Resistor & Fan Assembly
    GC0152401Courtesy of CHRYSLER GROUP, LLC
  4. Disconnect the upper coolant hose from the radiator.
  5. Disconnect the electrical connector from the cooling fan resistor (1) located on the cooling fan shroud.
    Fig 3: Engine Cooling Fan, Connector & Fasteners
    GC0152367Courtesy of CHRYSLER GROUP, LLC
  6. Disconnect the cooling fan electrical connector (3).
  7. Disconnect the lower coolant hose from the radiator.
  8. Recover the refrigerant from the refrigerant system. Refer to STANDARD PROCEDURE .
    Fig 4: A/C Liquid Line, A/C Discharge Line, A/C Condenser Tapping Block & Bolt
    GC0152540Courtesy of CHRYSLER GROUP, LLC
  9. Remove the bolt (4) and disconnect the A/C liquid line (1) and the A/C compressor discharge line (2) from the A/C condenser tapping block (3).
  10. Separate the A/C liquid line from the A/C compressor discharge line. Remove and discard the dual plane seals.
  11. Install plugs in, or tape over, the opened refrigerant line fittings and condenser ports.
    Fig 5: Latch Cable
    GC0084616Courtesy of CHRYSLER GROUP, LLC
  12. Press down the latch release (3) and remove the hood latch cable (2) from the latch.
    Fig 6: Front Impact Sensor & Connector
    GC0153793Courtesy of CHRYSLER GROUP, LLC
  13. Disconnect the wire harness connector (2) from the right and left front impact sensors (1). Refer to SENSOR, IMPACT, REMOVAL . It is not necessary to unbolt the sensor from the frame.
    Fig 7: Horn & Connector
    GC0153791Courtesy of CHRYSLER GROUP, LLC
  14. Disconnect the wire harness connector (1) from the horn (2).
  15. Disengage the wire harness from the bumper reinforcement.
    Fig 8: View Of Wire Harness
    GC0103128Courtesy of CHRYSLER GROUP, LLC
  16. Disengage the block heater wire harness retainer (1) from the upper core support.
    Fig 9: Throttle Body Inlet Hose, Turbocharger Outlet Hose & Cooling Fan
    GC0153790Courtesy of CHRYSLER GROUP, LLC
  17. Disconnect the throttle body inlet hose (1) and turbocharger outlet hose (2) at the lower quick disconnects located behind the cooling fan (3).
    Fig 10: Front Cooling Module Assembly & Fasteners
    GC0153119Courtesy of CHRYSLER GROUP, LLC
  18. Remove the four upper bolts (1), eight center bolts and washers (2), eight lower bolts and washers (3). Remove the front end module (4) from the vehicle.
    Fig 11: Turbocharger Bracket & Fasteners
    GC0153805Courtesy of CHRYSLER GROUP, LLC
  19. Remove the turbocharger bracket bolts (1).
  20. Remove and discard  the bracket nut (3).
  21. Remove the turbocharger bracket (2).
    Fig 12: Upper Heat Shield Bolts & Nuts
    GC0153792Courtesy of CHRYSLER GROUP, LLC
  22. Remove the turbocharger upper heat shield bolts (1). Remove and discard  the nuts (2).
    Fig 13: Charge Air Cooler Supply Hose, Heat Shield, Nuts & Bolts
    GC0153600Courtesy of CHRYSLER GROUP, LLC
  23. Remove the Charge Air Cooler (CAC) supply hose (5) from the turbocharger.
  24. Remove the catalytic converter heat shield (3).
    CAUTION:

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

    Fig 14: 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
  25. Disconnect the wastegate supply line from the actuator pump (2).
  26. Disconnect the turbocharger pressure sensor hose (1).
  27. Remove the coolant return line banjo bolt located on the rear side of the turbocharger. Discard the banjo washers.
  28. Remove the coolant supply banjo bolt (4) and position the line aside. Discard the banjo washers.
  29. Remove the oil supply line banjo bolt (3). Remove the line as an assembly. The oil supply and return lines must be replaced. The oil line banjo bolts and banjo washers must be replaced. 
  30. Remove the lower oil return line (5). The oil supply and return lines must be replaced. The oil line banjo bolts and banjo washers must be replaced. 
  31. Disconnect the turbocharger surge valve connector (6).
    NOTE:

    Remove the surge valve from the turbocharger. It will be necessary to install the surge valve onto the new turbocharger assembly.

  32. Raise and support vehicle.
    Fig 15: Front Exhaust Pipe Support Bolt & Flange Nuts
    GC0153120Courtesy of CHRYSLER GROUP, LLC
  33. Remove the exhaust flange nuts (1).
  34. Remove the front exhaust pipe support bolt (2).
    Fig 16: Catalytic Converter, Support Mount & Bolts
    GC0153601Courtesy of CHRYSLER GROUP, LLC
  35. Remove the nuts that secure the cross under pipe to the catalytic converter.
  36. Remove the front exhaust pipe and flange gasket.
  37. Remove the lower catalytic converter support mount (2).
  38. Lower the vehicle.
    Fig 17: Turbocharger, Catalytic Converter Clamp & Catalytic Converter Assembly
    GC0153788Courtesy of CHRYSLER GROUP, LLC
  39. Disconnect the upstream oxygen sensor connector.
  40. Loosen the catalytic converter clamp (2) at the turbocharger (1) and remove the converter assembly from vehicle.
    Fig 18: Converter/Turbo Gasket Ring
    GC0153789Courtesy of CHRYSLER GROUP, LLC
  41. Remove and discard  the converter to turbo seal ring (1).
    Fig 19: Covers/Caps
    GC0143919Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Install the (special tool #10368, Set, Universal Protective Cap) into the open bores on the turbo to avoid any foreign material to enter the turbocharger.

  42. Remove the two bolts that secure the shield to the exhaust manifold. Remove and discard  the nut.
  43. Remove the shield.
    Fig 20: Exhaust Manifold Nuts
    GC0153795Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The turbocharger has been removed for clarity in illustration.

  44. Remove and discard  the nine exhaust manifold nuts (1). Remove the nine washers.
  45. Remove and discard  the nine exhaust manifold studs.
    NOTE:

    The exhaust manifold nuts and studs must be replaced. The washers can be reused. The exhaust manifold gasket and the turbocharger to manifold gasket must be replaced. 

    Fig 21: Manifold/Turbocharger Nuts
    GC0153796Courtesy of CHRYSLER GROUP, LLC
  46. With the manifold removed, invert the manifold and turbocharger as an assembly. Remove and discard  the four nuts (1).
    NOTE:

    The turbocharger mounting nuts must be replaced.

  47. Lift the manifold up and off of the turbocharger. Remove and discard  the gasket.
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