Section 505 (Exhaust System & Turbocharger): Turbocharger: Installation

WARNING: This page is about a different car, the 2005 Jeep Liberty. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Turbocharger And Oil Lines

Courtesy of DAIMLERCHRYSLER CORP.

1 - UPPER HEAT SHIELD	7 - TURBOCHARGER WITH ACTUATOR
2 - OIL SUPPLY PIPE	8 - OIL RETURN PIPE
3 - BANJO BOLT	9 - GROMMET
4 - BRASS SEALS	10 - GASKET
5 - TO CHARGE AIR INLET HOSE	11 - EXHAUST MANIFOLD
6 - TO AIR CLEANER ASSEMBLY	12 - GASKET

Install a new exhaust manifold gasket and position the exhaust manifold into place. Hand tighten fasteners.

NOTE: After Tightening The Exhaust Manifold To Specification Using a Diagonal-Cross Pattern, Retrace The Pattern Checking The Correct Torque Value Again.

Tighten the exhaust manifold to cylinder head fasteners in a diagonal-cross pattern to 36 N.m (26.5 ft. lbs.). See Fig 1
Connect turbocharger to exhaust manifold with new gasket. See Fig 1. Torque retaining nuts to 32.4N.m.
Connect oil supply line at turbocharger. Torque banjo fitting to 24.5 N.m.(18 ft. lbs.). See Fig 1.
Raise and support the vehicle.
Connect the oil return pipe to the turbocharger with new gasket and tighten the fasteners to 10.8 N.m (95 in. lbs.).

Install the turbocharger support bracket and tighten fasteners to 24.5 N.m (18 ft. lbs.).

Fig 2: Exhaust At Turbo

Courtesy of DAIMLERCHRYSLER CORP.

1 - EXHAUST PIPE

2 - TURBOCHARGER

3 - BRACKET

4 - ENGINE OIL COOLER

Connect the front exhaust pipe to the turbocharger. See Fig 2.

Fig 3: Skid Plate
Courtesy of DAIMLERCHRYSLER CORP.

1 - SKID PLATE

2 - BOLTS (4)
Install the lower skid plate. See Fig 3.
Lower the vehicle.
Install the upper turbocharger heat shield. Tighten the fasteners to 24.5 N.m (18 ft. lbs.). See Fig 1.
Connect the turbocharger actuator vacuum hose to the actuator. See Fig 1.

Fig 4: Coolant Reservoir
Courtesy of DAIMLERCHRYSLER CORP.

1 - COOLANT RESERVOIR
Install the coolant reservoir. See Fig 4.

Fig 5: Air Cleaner Housing
Courtesy of DAIMLERCHRYSLER CORP.

1 - AIR CLEANER HOUSING

2 - INLET DUCT
Install the charge air outlet hose
Install the air cleaner assembly and connect the electrical connectors. See Fig 5.
Install engine cover (Refer to ENGINE - INSTALLATION) .
Refill cooling system. Refer to COOLING . .
Connect negative battery cable.