Turbocharger System: Turbocharger: Removal: Removal

WARNING: This page is about a different variant/trim than selected.

Disconnect and isolate the negative battery cable.
Remove the air cleaner body. Refer to BODY, AIR CLEANER, REMOVAL .
Recover the refrigerant from the refrigerant system. Refer to STANDARD PROCEDURE .
Raise and support the vehicle. Refer to HOISTING .
Remove the belly pan. Refer to BELLY PAN, REMOVAL .
Drain the cooling system. Refer to STANDARD PROCEDURE .
Remove the front fascia. Refer to FASCIA, FRONT, REMOVAL .

Fig 1: Left Headlamp & Fasteners
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Remove the right and left headlamp units (2).

Fig 2: Cooling Fan Resistor & Fan Assembly
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Disconnect the upper coolant hose from the radiator.
Disconnect the electrical connector from the cooling fan resistor (1) located on the cooling fan shroud.

Fig 3: Engine Cooling Fan, Connector & Fasteners
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Disconnect the cooling fan electrical connector (3).
Disconnect the lower coolant hose from the radiator.

Fig 4: A/C Liquid Line, A/C Discharge Line, A/C Condenser Tapping Block & Bolt
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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).
Separate the A/C liquid line from the A/C compressor discharge line. Remove and discard the dual plane seals.
Install plugs in, or tape over, the opened refrigerant line fittings and condenser ports.

Fig 5: Latch Cable
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Press down the latch release (3) and remove the hood latch cable (2) from the latch.

Fig 6: Front Impact Sensor & Connector
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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
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Disconnect the wire harness connector (1) from the horn (2).

Fig 8: Wire Harness Connector
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Disengage the wire harness connector (1) from the ambient air temperature sensor.

Fig 9: Wire Harness Retainer
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Disengage the wire harness retainer (1) from the bottom of the bumper reinforcement.

Fig 10: Throttle Body Inlet Hose, Turbocharger Outlet Hose & Cooling Fan
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Disconnect the throttle body inlet hose (1) and turbocharger outlet hose (2) at the lower quick disconnects located behind the cooling fan (3).

Fig 11: Front Cooling Module Assembly & Fasteners
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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 12: Turbocharger Bracket & Fasteners
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Remove the turbocharger support bracket bolts (1).
Remove and discard the bracket nut (3).
Remove the turbocharger bracket (2).

Fig 13: Upper Heat Shield Bolts & Nuts
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Remove the bolts (1), nuts (2) and the turbocharger upper heat shield. Discard the nuts (2).

Fig 14: Charge Air Cooler Supply Hose, Heat Shield, Nuts & Bolts
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Remove the bolt (4) and the Charge Air Cooler (CAC) supply hose (5) from the turbocharger outlet.
Remove the bolt (1), nuts (2) and the lower catalytic converter heat shield (3).

Fig 15: Downstream & Upstream Oxygen Sensors With Retainer
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Disengage the wire harness from the retainer (3) and disconnect the upstream oxygen sensor connector (1) and downstream oxygen sensor connector (2).

Fig 16: Front Exhaust Pipe Support Bolt & Flange Nuts
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Remove the exhaust flange nuts (1).
Remove the front exhaust pipe support bolt (2).

Fig 17: Exhaust Pipe Flange, Nuts & Gasket
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Remove the nuts (2) that secure the cross under pipe to the catalytic converter.
Remove the front exhaust pipe (1) and discard the flange gasket (3).

Fig 18: Catalytic Converter, Support Mount & Bolts
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Remove the bolts (3) from the catalytic converter support bracket (2).
Lower the vehicle.

Fig 19: Turbocharger, Catalytic Converter Clamp & Catalytic Converter Assembly
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Loosen the catalytic converter clamp (2) at the turbocharger (1) and remove the converter assembly (3) from vehicle.

Fig 20: Converter/Turbo Gasket Ring
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Remove and discard the converter to turbo seal ring (1).

Fig 21: Covers/Caps
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NOTE:
Install the (special tool #10368, Set, Universal Protective Cap) into the open ports of the turbocharger.

Fig 22: Turbocharger Bypass Solenoid Electrical Connector, Air Hose To Waste-Gate Solenoid Valve & Turbocharger Coolant Outlet
Courtesy of CHRYSLER GROUP, LLC
Unlock and disconnect the turbocharger surge valve wire harness connector (1).
Disconnect the wastegate actuator hose (2) from the turbocharger.
Remove the bolt (3) at the turbocharger coolant return tube and disconnect the tube from the coolant return pipe.

Fig 23: Coolant Return Tube Fitting At Turbocharger
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Remove the coolant return tube banjo bolt (1) and remove the turbocharger coolant return tube. Discard the banjo bolt washers.

Fig 24: Turbocharger Coolant Feed Banjo Bolt
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Remove the coolant supply tube banjo bolt (1) and position the tube aside. Discard the banjo bolt washers.

Fig 25: Engine Oil Cooler Heat Shields & Screws
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Remove the screws (1a) and remove the engine oil cooler heat shields (1b).

Fig 26: Turbocharger Oil Supply Tube Fitting At Oil Filter Housing
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CAUTION:
The oil supply and return lines MUST be replaced whenever the lines are loosened or removed.
Remove the oil supply tube banjo bolt (1) and remove the oil supply tube from the oil filter housing.

Fig 27: Turbocharger Oil Supply Tube & Fitting
Courtesy of CHRYSLER GROUP, LLC
Remove the oil supply tube banjo bolt (1) and remove the turbocharger oil supply tube. The oil supply and return tubes must be replaced. The banjo bolts and banjo bolt washers must be replaced.

Fig 28: Oil Return Tubes At Turbocharger & Crankcase Bolts & Fitting
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Remove the bolts (1) from the oil return tube at the turbocharger.
Remove the bolt (2) from the oil return tube at the crankcase.
Remove the banjo bolt (3) and remove the turbocharger oil return tube. The oil supply and return tubes must be replaced. The banjo bolts and banjo bolt washers must be replaced.

Fig 29: Exhaust Manifold Heat Shield & Nuts
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Remove the nuts (1) from the exhaust manifold heat shield (2).

Fig 30: Exhaust Manifold Heat Shield & Nut
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Remove the nut (1) and remove the exhaust manifold heat shield (2).

Fig 31: Exhaust Manifold Nuts
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NOTE:
The turbocharger has been removed for clarity in illustration.
Remove and discard the nine exhaust manifold nuts (1). Remove the nine washers and remove the exhaust manifold.

Fig 32: Turbocharger Heat Shield
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Remove the turbocharger gasket/heat shield (1).
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 33: Manifold/Turbocharger Nuts
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With the exhaust 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.
Lift the manifold up and off of the turbocharger. Remove and discard the gasket.

Fig 34: Surge Valve, Connector & Bolts
Courtesy of CHRYSLER GROUP, LLC
If replacing the turbocharger, remove the bolts (1) and surge valve (3). It will be necessary to install the surge valve on the replacement turbocharger.