ARTICLE BEGINNING EXHAUST SYSTEM AND...

ARTICLE BEGINNING

EXHAUST SYSTEM AND TURBOCHARGER

DESCRIPTION

DESCRIPTION - EXHAUST SYSTEM

The exhaust system components consist of a catalytic converter, intermediate pipe, muffler, clamps and support isolators. See Fig. 1.

Fig. 1: Exhaust SystemCourtesy of DAIMLERCHRYSLER CORP.

DIAGNOSIS AND TESTING

EXHAUST SYSTEM DIAGNOSIS

1 - FLEX PIPE

2 - CATALYTIC CONVERTER

3 - BAND CLAMP

4 - MUFFLER

5 - INTERMEDIATE PIPE

6 - BAND CLAMP

CONDITION POSSIBLE CAUSES CORRECTION

EXCESSIVE EXHAUST NOISE (UNDER HOOD)

1. Exhaust manifold cracked or broken.

1. Replace manifold.

2. Manifold to cylinder head 2. Tighten manifold and/or replace

of 69EXHAUST SYSTEM & TURBOCHARGER -2005 Chrysler PT Cruiser

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DIAGNOSIS AND TESTING - EXHAUST SYSTEM RESTRICTION CHECK

Exhaust system restriction can be checked by measuring back pressure using the DRB III(R) and PEP module pressure tester.

1. Disconnect and remove the upstream (before catalytic converter) oxygen sensor. (Refer to FUEL

SYSTEM/FUEL INJECTION/O2 SENSOR - REMOVAL)

2. Install the Exhaust Back Pressure Fitting Adaptor CH8519.

3. Connect the Low Pressure Sensor (15 psi) CH7063 to the back pressure fitting.

4. Following the PEP module instruction manual, connect all required cables to the DRB III(R) and PEP module. Select the available menu options on the DRBIII(R) display screen for using the digital pressure gauge function.

5. Apply the park brake and start the engine.

6. With transmission in Park or Neutral, raise engine speed to 2000 RPM. Monitor the pressure readings on the DRBIII(R). Back pressure should not exceed specified limit. Refer to specification in EXHAUST BACK PRESSURE LIMITS table.

7. If pressure exceeds maximum limits, inspect exhaust system for restricted component. For further catalytic converter inspection procedures, (Refer to EXHAUST SYSTEM/CATALYTIC

CONVERTER - INSPECTION). Replace component(s) as necessary.

leak. gasket.

3. Exhaust flex joint tomanifold leak.

3. Tighten fasteners or replace gasket.

4. Exhaust flex joint. 4. Replace catalytic converter assembly.

5. Pipe and shell noise from front exhaust pipe.

5. Characteristic of single wall pipes.

EXCESSIVE EXHAUST NOISE

1. Leaks at pipe joints. 1. Tighten or replace clamps at leaking joints.

2. Burned, blown, or rusted out exhaust pipe or muffler.

2. Replace muffler or exhaust pipes.

3. Restriction in muffler ortailpipe.

3. Remove restriction, if possible orreplace as necessary.

4. Catalytic converter material in muffler.

4. Replace muffler and converter assembly. Check fuel injection and ignition systems for proper operation.

WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME.

NOTE: For Special Tool identification, (Refer to EXHAUST SYSTEM - SPECIALTOOLS).



EXHAUST BACK PRESSURE LIMITS

INSPECTION

Inspect the exhaust pipes, catalytic converters, muffler, and resonators for cracked joints, broken welds and corrosion damage that would result in a leaking exhaust system. Inspect the clamps, support brackets, and insulators for cracks and corrosion damage.

ADJUSTMENTS

EXHAUST SYSTEM ALIGNMENT

A misaligned exhaust system is usually indicated by a vibration, rattling noise, or binding of exhaust system components. These noises are sometimes hard to distinguish from other chassis noises. Inspect exhaust system for broken or loose clamps, heat shields, insulators, and brackets. Replace or tighten as necessary. It is important that exhaust system clearances and alignment be maintained.

Perform the following procedures to align the exhaust system. Refer to Fig. 2 for exhaust system clearance specifications.

1. Loosen clamps and support brackets.

2. Align the exhaust system starting at the front, working rearward.

3. Tighten all clamps and brackets once alignment and clearances are achieved.

SPECIFICATIONS

EXHAUST SYSTEM CLEARANCE

1. Refer to the following illustration to adjust the exhaust system. See Fig. 2.

Exhaust Back Pressure Limit (Max)

Vehicle in Park/Neutral (no load) @2000 RPM 3.45 kPa (0.5 psi)

NOTE: Slip joint band clamps are spot welded to exhaust system. If a band clamp must be replaced, the spot weld must be ground off.



Fig. 2: Exhaust Clearance

Courtesy of DAIMLERCHRYSLER CORP.

1 - TUNNEL HEAT SHIELD


3 - BAND CLAMP

4 - FUEL TANK STRAP

5 - FLOOR PAN


7 - HEAT SHIELD

8 - SPARE TIRE

9 - MUFFLER

10 - REAR FASCIA

11 - TAIL PIPE

12 - HEAT SHIELD

13 - OXYGEN SENSOR


15 - TUNNEL HEAT SHIELD


17 - FUEL TANK

18 - TANK STRAP

19 - SUSPENSION LINKAGE




TORQUE - EXHAUST SYSTEM COMPONENTS

TORQUE - TURBOCHARGER COMPONENTS

SPECIAL TOOLS

EXHAUST SYSTEM

DESCRIPTION N.m Ft. Lbs. In. Lbs.

Fastener, Band Clamps 47 35 -

Fasteners, Catalytic Converter to Exhaust Manifold Flange

28 - 250

Fasteners, Intermediate Pipe Heat Shield 3.7 - 33

Fasteners, Support Brackets (Frame Rail Mounted) 8.5 - 75

Fasteners, Support Bracket (Rear Panel Mounted) 3.7 - 33

DESCRIPTION N.m Ft. Lbs. In. Lbs.

Fasteners, Charge Air Cooler 8 - 70

Hose Clamps, Charge Air Cooler 1.7 - 15

Banjo Fitting, Coolant Line 37 27 -

Brass Fitting, Coolant/Oil Line 41 30 -

Flared Fitting, Coolant/Oil Line 31 23 -

Elbow 28 - 250

Elbow Support Bracket - - -

M8 Fasteners 28 - 250

M10 Fasteners 54 40 -

Fasteners, Exhaust Manifold/Turbocharger Assembly to Cylinder Head

28 - 250

Fasteners, Heat Shield 28 - 250

Fasteners, Oil Return Tube 12 - 105

Turbocharger Support Bracket 54 40 -



Fig. 3: DRB III(R) & PEP Module - OT-CH6010ACourtesy of DAIMLERCHRYSLER CORP.



Fig. 4: Back Pressure Test Adapter - CH8519Courtesy of DAIMLERCHRYSLER CORP.

Fig. 5: Pressure Transducer CH7063


MUFFLER



REMOVAL

1. Raise vehicle on hoist and apply penetrating oil to band clamp fastener of component being removed.

2. Remove exhaust system ground strap at rear of muffler.

3. Loosen band clamp and remove support isolators at muffler. Remove muffler from intermediate pipe. See Fig. 6.

4. Clean ends of pipes and muffler to assure mating of all parts. Discard broken or worn isolators, rusted or overused clamps, supports, and attaching parts.

WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATING TIME.

NOTE: Do not use petroleum-based lubricants when removing/installing muffler or exhaust pipe isolators as it may compromise the life of the part. A suitable substitute is a mixture of liquid dish soap andwater.

NOTE: When replacement is required on any component of the exhaust system, you must use original equipment parts (or their equivalent).



Fig. 6: MufflerCourtesy of DAIMLERCHRYSLER CORP.

INSTALLATION

When assembling exhaust system do not tighten clamps until components are aligned and clearances are checked.

1. Install the muffler to intermediate pipe and the isolator supports to the underbody.

2. Working from the front of system; align each component to maintain position and properclearance with underbody parts. See Fig. 2. For clearance specifications (Refer to EXHAUST

SYSTEM - SPECIFICATIONS). Tighten band clamp to 47 N.m (35 ft. lbs.). See Fig. 7.

1 - CLAMP


3 - ISOLATOR

4 - CLAMP

5 - HANGER

6 - MUFFLER

7 - HANGER

8 - ISOLATOR

CAUTION: Band clamps should never be tightened such that the two sides of the clamps are bottomed out against the center hourglass shaped center block. Once this occurs, the clampband has been stretched and has lost its clamping force and



3. Connect the exhaust system ground strap.

Fig. 7: Band ClampCourtesy of DAIMLERCHRYSLER CORP.

4. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.

5. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.

INTERMEDIATE PIPE

must be replaced.

To replace the band clamp; remove the nut and peel back theends of the clamp until spot weld breaks. File or grind remaining weld material until pipe surface is smooth.

NOTE: Maintain proper clamp orientation when replacing with new clamp.

1 - CLAMP SIZE

2 - TORQUE SPECIFICATION



REMOVAL

1. Raise vehicle on hoist and apply penetrating oil to band clamp fastener of component being removed.

2. Remove muffler (Refer to EXHAUST SYSTEM/MUFFLER - REMOVAL).

3. Loosen band clamp and remove support isolator. Remove intermediate pipe from catalyticconverter pipe. See Fig. 8.

4. Clean ends of pipes and muffler to assure mating of all parts. Discard broken or worn isolators,rusted or overused clamps, supports, and attaching parts.

WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATING TIME.


NOTE: When replacement is required on any component of the exhaust system, you must use original equipment parts (or their equivalent).



Fig. 8: Intermediate PipeCourtesy of DAIMLERCHRYSLER CORP.

INSTALLATION

When assembling exhaust system do not tighten clamps until components are aligned and clearances are checked.

1. Install intermediate pipe and the isolator supports to the underbody. See Fig. 8.

2. Install muffler (Refer to EXHAUST SYSTEM/MUFFLER - INSTALLATION).

3. Working from the front of system; align each component to maintain position and proper clearance with underbody parts. See Fig. 2. For clearance specifications (Refer to EXHAUST

SYSTEM - SPECIFICATIONS).

4. Tighten band clamps to 47 N.m (35 ft. lbs.). See Fig. 9.

1 - CLAMP

2 - CATALYTIC CONVERTER PIPE


4 - ISOLATOR

5 - HANGER

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

To replace the band clamp; remove the nut and peel back theends of the clamp until spot weld breaks. File or grind remaining weld material until pipe surface is smooth.

NOTE: Maintain proper clamp orientation when replacing with new clamp.



Fig. 9: Band Clamp




CATALYTIC CONVERTER

DESCRIPTION

An under-floor catalytic converter inlet is attached to the exhaust manifold using fasteners and a gasket for sealing. See Fig. 10. A flex joint that is integral to the converter allows movement between the engine and the exhaust system. The converter outlet attaches to the intermediate pipe.

1 - CLAMP SIZE

2 - TORQUE SPECIFICATION



Fig. 10: Catalytic Converter - Typical


OPERATION

The three-way catalytic converter simultaneously converts three exhaust emissions into harmless gases.Specifically, HC and CO emissions are converted into water (H2O) and carbon dioxide (CO2). Oxides of Nitrogen (NOx) are converted into Nitrogen (N) and Oxygen. The three-way catalyst is most efficient in converting HC, CO and NOx at the stoichiometric air fuel ratio of 14.7:1.

The oxygen content in a catalyst is important for efficient conversion of exhaust gases. When a highoxygen content (lean) air/fuel ratio is present for an extended period, oxygen content in a catalyst can reach a maximum. When a rich air/fuel ratio is present for an extended period, the oxygen content in the catalyst can become totally depleted. When this occurs, the catalyst fails to convert the gases. This isknown as catalyst "punch through."

Catalyst operation is dependent on its ability to store and release the oxygen needed to complete theemissions-reducing chemical reactions. As a catalyst deteriorates, its ability to store oxygen is reduced. Since the catalyst's ability to store oxygen is somewhat related to proper operation, oxygen storage can be used as an indicator of catalyst performance. Refer to POWERTRAIN DIAGNOSTIC

1 - FLEX JOINT


3 - OXYGEN SENSOR



PROCEDURES article for diagnosis of a catalyst related Diagnostic Trouble Code (DTC).

The combustion reaction caused by the catalyst releases additional heat in the exhaust system, causing temperature increases in the area of the reactor under severe operating conditions. Such conditions canexist when the engine misfires or otherwise does not operate at peak efficiency. Do not remove spark plug wires from plugs or by any other means short out cylinders. Failure of the catalytic converter can occur due to temperature increases caused by unburned fuel passing through the converter. This deterioration of the catalyst core can result in excessively high emission levels, noise complaints, and exhaust restrictions.

Unleaded gasoline must be used to avoid ruining the catalyst core. Do not allow engine to operate above 1200 RPM in neutral for extended periods over 5 minutes. This condition may result in excessive exhaust system/floor pan temperatures because of no air movement under the vehicle.

The flex joint allows flexing as the engine moves, preventing breakage that could occur from the back-and-forth motion of a transverse mounted engine.

REMOVAL

1. Loosen intermediate pipe-to catalytic converter clamp.

2. Remove muffler/intermediate pipe insulators as necessary to slide muffle/intermediate pipe assembly out of catalytic converter.

3. 1.6L Engine - Disconnect upstream oxygen sensor electrical connector.

4. Disconnect downstream oxygen sensor electrical connector. See Fig. 11.

CAUTION: Due to exterior physical similarities of some catalytic converters with pipe assemblies, extreme care should be taken with replacement parts. There are internal converter differences required in some parts of the country (particularly vehicles built for States with strict emission requirements) and between model years.

WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME.

NOTE: Before replacing a catalytic converter, determine the root cause of failure. Most catalytic converter failures are caused by air, fuel or ignition problems. Refer to POWERTRAIN DIAGNOSTIC PROCEDURES article forrepair procedures.




Fig. 11: Downstream 1/2 Oxygen Sensor - Typical


5. Remove catalytic converter to exhaust manifold attaching fasteners and remove converter from vehicle. See Fig. 12, Fig. 13, Fig. 14 or Fig. 15.

6. Remove and discard flange gasket.

1 - DOWN STREAM O2 SENSOR

2 - UP STREAM O2 SENSOR

NOTE: When replacement is required on any component of the exhaust system, original equipment parts (or equivalent) must be used.



Fig. 12: Converter To Exhaust Manifold Connection - 1.6L


1 - GASKET

2 - NUT


4 - BOLT

5 - SUPPORT BRACKET





1 - FLAG NUT

2 - GASKET

3 - BOLT

4 - NUT






1 - GASKET


3 - NUT



Fig. 15: Converter To Exhaust Manifold Connection - 2.4L Turbo


1 - FLAG NUT

2 - GASKET

3 - NUT

4 - BOLT




INSPECTION

Check catalytic converter for a flow restriction. (Refer to EXHAUST SYSTEM - DIAGNOSIS AND

TESTING) Exhaust System Restriction Check for procedure.

Visually inspect the catalytic converter element by using a borescope or equivalent. Remove oxygen sensor(s) and insert borescope. If borescope is not available, remove converter and inspect element using a flashlight. Inspect element for cracked or melted substrate.

INSTALLATION

1. Assemble catalytic converter to exhaust manifold connection. Use a new flange gasket.

2. Tighten the catalytic converter to exhaust manifold fasteners to 28 N.m (250 in. lbs.). See Fig. 12, Fig. 13, Fig. 14 or Fig. 15.

3. Install intermediate pipe and muffler (Refer to EXHAUST SYSTEM/INTERMEDIATE PIPE -

INSTALLATION).

4. Working from the front of system; align each component to maintain position and proper clearance with underbody parts. See Fig. 2. For clearance specifications (Refer to EXHAUST SYSTEM - SPECIFICATIONS).

5. Tighten band clamps to 47 N.m (35 ft. lbs.).

6. If removed, install downstream oxygen sensor. See Fig. 11.

7. Connect downstream oxygen sensor electrical connector.

8. 1.6L Engine - Connect upstream oxygen sensor connector.


10. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if

WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME.

NOTE: Before replacing a catalytic converter, determine the root cause of failure. Most catalytic converter failures are caused by air, fuel or ignition problems. (Refer to POWERTRAIN DIAGNOSTIC PROCEDURES article fortest procedures.

NOTE: When assembling exhaust system do not tighten clamps until all components are aligned and clearances are checked.

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



needed.

SUPPORT BRACKETS AND ISOLATORS

REMOVAL

1. Disconnect isolator from exhaust system component.

2. Remove screws attaching isolator bracket to underbody. See Fig. 16.

3. Remove isolator assembly. See Fig. 16.

Fig. 16: Exhaust System Isolator And Bracket


INSTALLATION

1. Position isolator bracket to underbody and install attaching screws. See Fig. 16. Tighten bracket screws to frame rail to 8.5 N.m (75 in. lbs.) and bracket screws to the rear panel to 3.7 N.m (33 in. lbs.).

2. Connect isolator to exhaust system component.


4. Check the exhaust system for contact with the body panels. Make the necessary adjustments, ifneeded.



HEAT SHIELDS

DESCRIPTION

Heat shields are needed to protect both the vehicle and the environment from the high temperatures developed in the vicinity of the catalytic converter. See Fig. 17, Fig. 18, Fig. 19 and Fig. 20.

Fig. 17: Heat Shield - Engine WiringCourtesy of DAIMLERCHRYSLER CORP.

CAUTION: Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan heat shield on cars if equipped. Light over-spray near the edges is permitted. Application of coating will greatly reduce the efficiency of the heat shields resulting in excessive floor pan temperatures and objectionable fumes.

1 - HEAT SHIELD

2 - NUT

3 - NUT



Fig. 18: Heat Shield - Catalytic Converter


1 - HEAT SHIELD

2 - NUT



Fig. 19: Heat Shield - Intermediate Pipe


1 - SCREW

2 - HEAT SHIELD

3 - NUT

4 - SCREW



Fig. 20: Heat Shield - Muffler


REMOVAL

1. Raise vehicle on hoist.

2. Remove fasteners attaching heat shield. See Fig. 17, Fig. 18, Fig. 19 or Fig. 20.

3. Remove heat shield(s).

INSTALLATION

1 - HEAT SHIELD

2 - FASTENER



1. Position heat shield(s) to underbody.

2. Install heat shield fasteners. See Fig. 17, Fig. 18, Fig. 19 or Fig. 20.

3. Inspect heat shield to exhaust system clearances and adjust as necessary. See Fig. 2. For clearance specifications (Refer to EXHAUST SYSTEM - SPECIFICATIONS).

4. Lower vehicle.


6. Check the exhaust system for contact with the body panels. Make the necessary adjustments, ifneeded.

TURBOCHARGER SYSTEM

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - TURBOCHARGER

Check for Diagnostic Trouble Codes (DTC'S) stored in PCM memory. If any DTC'S are present, refer to POWERTRAIN DIAGNOSTIC PROCEDURES article.

TURBOCHARGER DIAGNOSIS

DIAGNOSIS AND TESTING - SRT-4

Tips Click a link to view tip

Tech1 Tip: Oil burning may be PCV valve, not turbo seals

CONDITION POSSIBLE CAUSES

Low boost pressure, lack of power Clogged air filter

Leaks between engine and turbocharger

Exhaust restriction

Restriction in charge air cooler hose(s)

Wastegate stuck open

Wastegate actuator malfunction

Seized turbocharger shaft

Overboost Wastegate stuck shut

Wastegate actuator malfunction

Noisy operation or vibration Leak(s) in charge air cooler hose(s)

Intake or exhaust leaks

Oil starvation

Worn turbocharger bearings

Damaged turbine/compressor fins

Blue smoke from exhaust Oil return line blocked

Engine breather clogged

Turbocharger shaft seals damaged



During normal operation the SRT-4 turbocharger will emit a very high frequency whistle at full boost 68.9 - 103.4 kPa (10 - 15 psi) during WOT acceleration.

During throttle tip-out, the surge valve will emit a light air "woosh" noise. If there is excessive NVH orother air leak/turbocharger noises, the intercooler plumbing or turbocharger control system may be compromised.

TO identify the source of the concern, check for Diagnostic Trouble Codes (DTC'S) stored in PCM memory. If any DTC'S are present, refer to POWERTRAIN DIAGNOSTIC PROCEDURES article.

If there are no DTC'S stored, use the following chart.

CONDITION POSSIBLE CAUSES CORRECTION

UNDERBOOST - 20.6 -27.5 kPa and turbocharger lag at WOT with some air

leak noiseOVERBOOST - 103.4

kPa (10 psi) or more even at part throttle (could be as high as 137.8 kPa (20

psi) or more). A"Fluttering" noise can be heard during overboost.

CAUTION: Engine

damage can result from prolonged Overboost.

Waste Gate control hose plumbing compromised/disconnected

(Refer to EXHAUST

SYSTEM/TURBOCHARGER

SYSTEM/CHARGE AIR COOLER AND PLUMBING -

INSTALLATION)

UNDERBOOST - 27.5 -62 kPa (4 - 9 psi) @ WOT with "horse laugh" on throttle tip-out.

Surge valve control hose plumbing compromised.

Repair plumbing (Refer to

EXHAUST SYSTEM/TURBOCHARGER

SYSTEM/CHARGE AIR

COOLER AND PLUMBING -

INSTALLATION)

NORMAL BOOST - but turbocharger lag and "horse laugh" noise on throttle tip-out.

Surge valve scroll and vacuum feeds reversed

Reverse vacuum lines (Refer to

EXHAUST

SYSTEM/TURBOCHARGER SYSTEM/SOLENOID -

INSTALLATION)

UNDERBOOST - 0-20.6kPa (0-3 psi) a WOT with loud air leak noise outside vehicle. Turbochargermay emit a "howling" noise.

Intercooler plumbing hose disconnected

Inspect plumbing and install (Refer to EXHAUST SYSTEM/TURBOCHARGER

SYSTEM/CHARGE AIR

COOLER AND PLUMBING -INSTALLATION)

Very rough idle TIP/MAP sensor hoses connectedimproperly or TIP disconnected

Inspect hosed (Refer to

EXHAUST SYSTEM/TURBOCHARGER

SYSTEM/LINES AND

HOSES - INSTALLATION)



TURBOCHARGER

DESCRIPTION

The turbocharger is an exhaust-driven supercharger which increases the pressure and density of the airentering the engine. With the increase of air entering the engine, more fuel can be injected into the cylinders, which creates more power during combustion.

The turbocharger assembly consists of four (4) major component systems. See Fig. 21:

� Turbine section

� Compressor section

� Bearing housing

� Wastegate

CAUTION: The turbocharger is a performance part and must not be tampered with. Tampering with the wastegate components can reduce durability by increasing cylinder pressure and thermal loading due to incorrect inlet and exhaust manifold pressure. Poor fuel economy and failure to meet regulatory emissions laws may result. Increasing the turbocharger boost WILL NOT increase engine power.



Fig. 21: Turbocharger - Typical


OPERATION

Exhaust gas pressure and energy drive the turbine, which in turn drives a centrifugal compressor that compresses the inlet air, and forces the air into the engine through the charge air cooler and plumbing. Since heat is a by-product of this compression, the air must pass through a charge air cooler to cool the

1 - TURBINE SECTION

2 - EXHAUST GAS

3 - BEARING HOUSING

4 - COMPRESSOR SECTION

5 - INLET AIR

6 - COMPRESSED AIR TO ENGINE

7 - EXHAUST GAS

8 - EXHAUST GAS TO EXHAUST PIPE



incoming air and maintain power and efficiency.

Increasing air flow to the engine provides:

� Improved engine performance

� Improved operating economy

� Altitude compensation

The turbocharger also uses a wastegate, which regulates intake manifold air pressure and prevents over boosting at high engine speeds. When the wastegate valve is closed, all of the exhaust gases flow through the turbine wheel. As the intake manifold pressure increases, the wastegate actuator opens the valve, diverting some of the exhaust gases away from the turbine wheel. This limits turbine shaft speed and air output from the impeller. See Fig. 22.



Fig. 22: Wastegate OperationCourtesy of DAIMLERCHRYSLER CORP.

The turbocharger is cooled by engine coolant. The coolant is delivered to the turbocharger by a supply line that connects from engine block to the turbocharger. A coolant return line connects the turbocharger to heater tubes.

The turbocharger is lubricated by engine oil that is pressurized, cooled, and filtered. The oil is delivered to the turbocharger by a supply line that is tapped into the cylinder block. The oil travels into the bearing housing, where it lubricates the shaft and bearings. See Fig. 23. A return pipe at the bottom of thebearing housing, routes the engine oil back to the crankcase.

1 - SIGNAL LINE

2 - EXHAUST BYPASS VALVE

3 - WASTEGATE

4 - EXHAUST

5 - TURBINE

6 - EXHAUST BYPASS VALVE

7 - WASTEGATE

8 - EXHAUST

9 - TURBINE

10 - SIGNAL LINE



Fig. 23: Turbocharger Oil Supply And DrainCourtesy of DAIMLERCHRYSLER CORP.

The most common turbocharger failure is bearing failure related to repeated hot shutdowns withinadequate "cool-down" periods. A sudden engine shut down after prolonged operation will result in the transfer of heat from the turbine section of the turbocharger to the bearing housing. This causes the oil to overheat and break down, which causes bearing and shaft damage the next time the vehicle is started.

Letting the engine idle after extended operation allows the turbine housing to cool to normal operating temperature. The following chart should be used as a guide in determining the amount of engine idle time required to sufficiently cool down the turbocharger before shut down, depending upon the type of driving and the amount of cargo.

1 - BEARINGS

2 - OIL SUPPLY (FROM ENGINE BLOCK)

3 - OIL RETURN (TO OIL PAN)



REMOVAL - TURBOCHARGER

1. Disconnect negative battery cable.

2. Drain cooling system (Refer to COOLING/ENGINE - STANDARD PROCEDURE -

DRAINING COOLING SYSTEM) .

3. Remove air cleaner housing and lid. Refer to AIR CLEANER HOUSING .

4. Disconnect clean air hose from turbocharger. See Fig. 24.

TURBOCHARGER "COOL DOWN" CHART

DrivingConditions

Idle Time (in minutes)Before Shut Down

Normal Driving Not required

Aggressive Driving or Heavily Loaded 3

Trailer Tow 5

CAUTION: IF TURBOCHARGER IS REPLACED DUE TO A BEARING FAILURE, REPLACEMENT OF THE OIL PRESSURE FEED LINE IS REQUIRED. OIL RETURN TUBE SHOULD BE CLEANED ALSO.

NOTE: The turbocharger and exhaust manifold are serviced as an assembly. Do Not attempt to remove the turbocharger from the exhaust manifold. Exhaust leaks will result. It is recommended that the turbocharger elbow be replaced along with the turbocharger/exhaust manifold assembly.



Fig. 24: Clean Air Hose - 2.4L Turbo


5. Disconnect throttle and speed control cables at throttle body.

6. Disconnect electrical connectors from the following components:

� Inlet Air Temperature (IAT) Sensor

� MAP Sensor

� IAC Motor

� Throttle Position Sensor

1 - CLEAN AIR HOSE

2 - TURBOCHARGER



� Ignition Coil Capacitor

� Upstream Oxygen Sensor

7. Disconnect air inlet hose at throttle body. See Fig. 25.

Fig. 25: Charge Air Cooler Hoses


1 - HOSE - CHARGE AIR COOLER TO THROTTLEBODY

2 - CHARGE AIR COOLER

3 - HOSE - TURBOCHARGER TO CHARGE AIR



8. Disconnect vacuum hoses at throttle body and upper intake manifold.

9. Remove upper intake manifold support bracket. See Fig. 26.

Fig. 26: Support Bracket


10. Remove upper intake manifold (Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD -REMOVAL) .

COOLER

1 - FASTENERS

2 - UPPER INTAKE MANIFOLD SUPPORT BRACKET

CAUTION: Cover lower intake manifold opening with suitable cover to prevent any foreign objects from entering.



11. Remove turbocharger lower heat shield. See Fig. 30.

12. Disconnect oil supply line at turbocharger. See Fig. 27.

13. Remove coolant return line. See Fig. 27.

Fig. 27: Turbocharger Lines And Hoses


1 - OIL SUPPLY LINE

2 - COOLANT RETURN LINE

3 - COOLANT SUPPLY LINE

4 - OIL RETURN TUBE



14. Disconnect vacuum hoses from turbocharger.


16. Disconnect muffler ground strap. Remove muffler (Refer to EXHAUST SYSTEM/MUFFLER -REMOVAL).

17. Disconnect downstream oxygen sensor.

18. Remove fasteners securing catalytic converter to exhaust manifold. See Fig. 28.

19. Remove catalytic converter and intermediate pipe as an assembly.



Fig. 28: Converter to Exhaust Manifold Connection - 2.4L TurboCourtesy of DAIMLERCHRYSLER CORP.

20. Remove turbocharger to charge air cooler hose assembly. See Fig. 29.

Fig. 29: Charge Air Cooler Hose

1 - FLAG NUT

2 - GASKET

3 - NUT

4 - BOLT





21. Remove turbocharger elbow support bracket. See Fig. 30.

22. Remove turbocharger support bracket. See Fig. 30.

23. Remove oil return tube. See Fig. 27.

24. Remove turbocharger coolant supply line. See Fig. 27.

25. Remove turbocharger upper heat shield. See Fig. 30.

26. Remove turbocharger elbow. See Fig. 30.


2 - HOSE - TURBOCHARGER TO CHARGE AIRCOOLER

3 - NUT



Fig. 30: Turbocharger Brackets And Heat ShieldsCourtesy of DAIMLERCHRYSLER CORP.

27. Remove lower exhaust manifold fasteners that are accessible while vehicle is on hoist.

28. Lower vehicle.

29. Remove upper exhaust manifold fasteners.

30. Remove turbocharger/exhaust manifold assembly from above/between the engine and cowl panel.

31. Remove and discard exhaust manifold gasket.

INSPECTION - TYPICAL TURBOCHARGER

Visually inspect the turbocharger and exhaust manifold gasket surfaces. Replace stripped or eroded mounting studs.

1. Visually inspect the turbocharger for cracks. The following cracks are NOT acceptable:

� Cracks in the turbine and compressor housing that go completely through.

� Cracks in the mounting flange that are longer than 15 mm (0.6 in.).

� Cracks in the mounting flange that intersect bolt through-holes.

� Two (2) Cracks in the mounting flange that are closer than 6.4 mm (0.25 in.) together.

2. Visually inspect the impeller and compressor wheel fins for nicks, cracks, or chips.

3. Visually inspect the turbocharger compressor housing for an impeller rubbing condition. See Fig. 31. Replace the turbocharger if the condition exists.

4. Measure the turbocharger axial end play:

a. Install a dial indicator. Zero the indicator at one end of travel.

b. Move the impeller shaft fore and aft and record the measurement. Allowable end play is 0.038 mm (0.0015 in.) MIN. and 0.089 mm (0.0035 in.) MAX. If the recorded measurement falls outside these parameters, replace the turbocharger assembly.

5. Measure the turbocharger bearing radial clearance:

a. Insert a narrow blade or wire style feeler gauge between the compressor wheel and thehousing.

b. Gently push the compressor wheel toward the housing and record the clearance.

c. With the feeler gauge in the same location, gently push the compressor wheel away from the housing and again record the clearance.

d. Subtract the smaller clearance from the larger clearance. This is the radial bearing clearance.

e. Allowable radial bearing clearance is 0.326 mm (0.0128 in.) MIN. and 0.496 mm (0.0195 in.) MAX. If the recorded measurement falls outside these specifications, replace the turbocharger assembly.

1 - UPPER/LOWER HEAT SHIELDS

2 - TURBOCHARGER SUPPORT BRACKET

3 - ELBOW

4 - ELBOW SUPPORT BRACKET



Fig. 31: Inspect Compressor Housing for Impeller Rubbing Condition


INSTALLATION - TURBOCHARGER

1. Clean gasket sealing surfaces. Replace exhaust manifold gasket. DO NOT APPLY SEALER TO

GASKET.

2. Turbocharger/exhaust manifold assembly is installed from above/between the engine and cowl panel.

3. Position turbocharger/exhaust manifold assembly in place. Gradually tighten fasteners, starting at

CAUTION: IF TURBOCHARGER IS REPLACED DUE TO A BEARING FAILURE, REPLACEMENT OF THE OIL PRESSURE FEED LINE IS REQUIRED. OIL RETURN TUBE SHOULD BE CLEANED ALSO.

NOTE: The turbocharger and exhaust manifold are serviced as an assembly. Do Not attempt to remove the turbocharger from the exhaust manifold. Exhaust leaks will result. It is recommended that the turbocharger elbow be replaced along with the turbocharger/exhaust manifold assembly.

NOTE: Stainless steel layer of exhaust manifold gasket goes against cylinder head, graphite layer of gasket goes against manifoldsurface.



center and progressing outward in both directions to 28 N.m (250 in. lbs.). See Fig. 32. Raise andlower vehicle for fastener access as necessary. Repeat tightening procedure until all fasteners are at specified torque.

Fig. 32: Exhaust Manifold Tightening SequenceCourtesy of DAIMLERCHRYSLER CORP.

4. Install turbocharger elbow. Torque fasteners to 28 N.m (250 in. lbs.). See Fig. 30.

5. Install turbocharger upper heat shield. Torque fasteners to 28 N.m (250 in. lbs.). See Fig. 30.

6. Install turbocharger coolant supply line. Install NEW washers. See Fig. 33. Torque banjo fitting bolt to 30 N.m (22 ft. lbs.). Torque flared fitting to 31 N.m (23 ft. lbs.). See Fig. 27.



Fig. 33: Banjo Bolt and Washers


7. Replace oil return tube gasket. Install oil return tube. Torque fasteners to 12 N.m (105 in. lbs.).Make sure heat shield for oil return line is properly installed. See Fig. 27.

8. Install turbocharger support bracket. Torque M8 fasteners to 28 N.m (250 in. lbs.) and M10 fasteners to 54 N.m (40 ft. lbs.). See Fig. 30.

9. Install turbocharger elbow support bracket. See Fig. 30.

10. Install turbocharger to charge air cooler hose assembly. See Fig. 29.

11. Install catalytic converter and intermediate pipe as an assembly.

12. Install fasteners securing catalytic converter to exhaust manifold. See Fig. 28. Torque fasteners to 28 N.m (250 in. lbs.).

13. Install muffler. Connect muffler ground strap. (Refer to EXHAUST SYSTEM/MUFFLER -

INSTALLATION).

14. Connect downstream oxygen sensor.

15. Lower vehicle.

1 - BANJO BOLT

2 - WASHERS



16. Connect vacuum hoses to turbocharger.

17. Install coolant return line. Install NEW washers. See Fig. 33. Torque banjo fitting bolt to 30 N.m (22 ft. lbs.). See Fig. 27.

18. Connect oil supply line at turbocharger. Torque flared fitting to 31 N.m (23 ft. lbs.). See Fig. 27.

19. Install turbocharger lower heat shield. Torque fasteners to 28 N.m (250 in. lbs.). See Fig. 30.

20. Install upper intake manifold. Refer to INTAKE MANIFOLD .

21. Install upper intake manifold support bracket. See Fig. 26.

22. Connect vacuum hoses at throttle body and upper intake manifold.

23. Connect air inlet hose at throttle body. See Fig. 25.

24. Connect electrical connectors to the following components:

� Inlet Air Temperature (IAT) Sensor

� MAP Sensor

� IAC Motor

� Throttle Position Sensor

� Ignition Coil Capacitor

� Upstream Oxygen Sensor

25. Connect throttle and speed control cables at throttle body.

26. Connect clean air hose to turbocharger. See Fig. 24.

27. Install air cleaner housing and lid. Refer to AIR CLEANER HOUSING .

28. Fill cooling system (Refer to COOLING/ENGINE - STANDARD PROCEDURE) .

29. Change oil and filter.

30. Connect negative battery cable.



CHARGE AIR COOLER AND HOSES

REMOVAL

REMOVAL - CHARGE AIR COOLER HOSES

HOSE - CHARGE AIR COOLER TO THROTTLE BODY

1. Remove air cleaner housing. Refer to AIR CLEANER HOUSING .


3. Disconnect positive battery cable.

4. Remove battery and battery tray (Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY -

NOTE: The lower heat shield tabs must over lap the upper heat shield to prevent fatiguing and premature failure of the union.



REMOVAL) .

5. Remove battery tray support bracket.

6. Loosen hose clamp at charge air cooler. See Fig. 34.

7. Dislodge hose from charge air cooler.

8. Disconnect Inlet Air Temperature (IAT) sensor connector. See Fig. 35.

9. Disconnect Throttle Inlet Pressure (TIP) hose from charge air cooler hose. See Fig. 35.

10. Loosen hose clamp at throttle body.

11. Remove charge air cooler hose.

Fig. 34: Charge Air Cooler Hoses




Fig. 35: IAT Sensor - 2.4L TurboCourtesy of DAIMLERCHRYSLER CORP.

HOSE - TURBOCHARGER TO CHARGE AIR COOLER


2. Loosen hose clamp at charge air cooler. See Fig. 36.

1 - HOSE - CHARGE AIR COOLER TO THROTTLE BODY


3 - HOSE - TURBOCHARGER TO CHARGE AIR COOLER

1 - HOSE - CHARGE AIR COOLER TO THROTTLE BODY

2 - IAT SENSOR

3 - TIP HOSE



3. Dislodge hose from charge air cooler.

4. Loosen hose clamp at turbocharger. See Fig. 34.

5. Dislodge hose from turbocharger.

6. Remove nuts securing charge air cooler hose to structural collar. See Fig. 36.

7. Remove charge air cooler hose.

Fig. 36: Charge Air Cooler HoseCourtesy of DAIMLERCHRYSLER CORP.


2 - HOSE - TURBOCHARGER TO CHARGE AIR COOLER



REMOVAL - CHARGE AIR COOLER

1. Drain cooling system (Refer to COOLING/ENGINE - STANDARD PROCEDURE) .



4. Disconnect positive battery cable.

5. Remove battery and battery tray (Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY -REMOVAL) .

6. Remove grille (Refer to BODY/EXTERIOR/GRILLE - REMOVAL) .

7. Remove upper radiator closure panel and center brace (Refer to

BODY/EXTERIOR/RADIATOR CLOSURE PANEL - REMOVAL) . See Fig. 37.

Fig. 37: Upper Radiator Closure Panel and Center Brace

3 - NUT




8. Remove front bumper fascia (Refer to FRAME & BUMPERS/BUMPERS/FRONT FASCIA -

REMOVAL) .

9. Remove front bumper (Refer to FRAME & BUMPERS/BUMPERS/FRONT BUMPER REINFORCEMENT - REMOVAL) .

10. Loosen charge air cooler hose clamps. Disconnect charge air cooler hoses. See Fig. 34 and Fig.

36.

11. Remove radiator fan (Refer to COOLING/ENGINE/RADIATOR FAN - REMOVAL) . See Fig. 38.

12. Remove charge air cooler fasteners. See Fig. 38.

13. Remove radiator (Refer to COOLING/ENGINE/RADIATOR - REMOVAL) .

14. Remove charge air cooler.

1 - UPPER RADIATOR CLOSURE PANEL

2 - CENTER BRACE



Fig. 38: Cooling Module - 2.4L Turbo


INSTALLATION

INSTALLATION - CHARGE AIR COOLER HOSES

1 - RADIATOR FAN FASTENERS

2 - CHARGE AIR COOLER FASTENERS

3 - RADIATOR FAN CONNECTOR




HOSE - CHARGE AIR COOLER TO THROTTLE BODY

1. Position hose to mounting location.

2. Connect hose to throttle body.

3. Connect hose to charge air cooler. See Fig. 34.

4. Tighten hose clamps to 1.7 N.m (15 in. lbs.).

5. Connect Throttle Inlet Pressure (TIP) hose to charge air cooler hose. See Fig. 35.

6. Connect Inlet Air Temperature (IAT) sensor connector. See Fig. 35.

7. Install battery tray support bracket.

8. Install battery tray and battery (Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY -

INSTALLATION) .

9. Connect positive battery cable.


11. Install air cleaner housing. Refer to AIR CLEANER HOUSING .

HOSE - TURBOCHARGER TO CHARGE AIR COOLER

1. Position hose to mounting location.

2. Temporarily install nuts securing charge air cooler hose to structural collar. See Fig. 36.

3. Connect hose to turbocharger. See Fig. 34.

4. Connect hose to charge air cooler. See Fig. 36.

5. Tighten hose clamps to 1.7 N.m (15 in. lbs.).

6. Tighten nuts securing charge air cooler hose to structural collar. See Fig. 36.

7. Lower vehicle.

INSTALLATION - CHARGE AIR COOLER

1. Position charge air cooler to mounting location.

NOTE: When lowering radiator, make sure lower radiator pins engage properly through charge air cooler tabs. See Fig. 39.



Fig. 39: Charge Air Cooler Locating Tab


2. Install radiator (Refer to COOLING/ENGINE/RADIATOR - INSTALLATION) .

3. Install fasteners attaching charge air cooler to radiator. Torque fasteners to 8 N.m (70 in. lbs.). See Fig. 38.

4. Install radiator fan (Refer to COOLING/ENGINE/RADIATOR FAN - INSTALLATION) .

5. Connect charge air cooler hoses. Tighten hose clamps to 1.7 N.m (15 in. lbs.) See Fig. 34 and Fig.

36.

6. Install front bumper (Refer to FRAME & BUMPERS/BUMPERS/FRONT BUMPER

REINFORCEMENT - INSTALLATION) .

7. Install front bumper fascia (Refer to FRAME & BUMPERS/BUMPERS/FRONT FASCIA -

INSTALLATION) .

8. Install upper radiator closure panel and center brace (Refer to BODY/EXTERIOR/RADIATOR

CLOSURE PANEL - INSTALLATION) . See Fig. 37.

1 - LOCATING TAB

2 - LOWER RADIATOR SUPPORT CROSSMEMBER

3 - RADIATOR MOUNT BUSHING




9. Install grille (Refer to BODY/EXTERIOR/GRILLE - INSTALLATION) .

10. Install battery tray and battery (Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY -INSTALLATION) .

11. Connect positive battery cable.




LINES AND HOSES

REMOVAL - LINES AND HOSES

NOTE: For line and hose location, refer to Fig. 40.



Fig. 40: Turbocharger Lines and Hoses


COOLANT SUPPLY LINE



1 - OIL SUPPLY LINE



4 - OIL RETURN TUBE



3. Remove banjo bolt from coolant supply line at turbocharger. See Fig. 41.

4. Disconnect coolant supply line flared fitting from brass fitting at engine block. See Fig. 42.

5. Remove coolant supply line.

Fig. 41: Coolant Lines - Banjo FittingsCourtesy of DAIMLERCHRYSLER CORP.


2 - BANJO BOLTS - 30 N.m (22 ft. lbs.)




Fig. 42: Coolant Supply Line - Engine Block Fitting


COOLANT RETURN LINE



3. Disconnect Inlet Air Temperature (IAT) sensor connector. See Fig. 35.

4. Disconnect Throttle Inlet Pressure (TIP) hose from charge air cooler hose. See Fig. 35.

5. Loosen hose clamp at throttle body.

6. Disconnect charge air cooler hose from throttle body. Reposition charge air cooler hose.

7. Remove fastener securing coolant return line bracket to cylinder head cover stud. See Fig. 43.

1 - BRASS FITTING - 41 N.m (30 ft. lbs.)

2 - FLARED FITTING - 31 N.m (23 ft. lbs.)




8. Remove hose clamp from coolant return line at heater tube. See Fig. 43. Disconnect hose from heater tube.

9. Remove banjo bolt from coolant return line at turbocharger. See Fig. 41.

10. Remove coolant return line.

Fig. 43: Coolant Return Line Bracket


OIL SUPPLY LINE


2. Remove elbow support bracket. See Fig. 44.

1 - NUT


3 - HOSE CLAMPS



3. Disconnect oil supply line flared fitting from brass fitting at engine block. See Fig. 45.

4. Lower vehicle.

5. Disconnect oil supply line flared fitting from brass fitting at turbocharger. See Fig. 46.

6. Remove oil supply line.

Fig. 44: Turbocharger Brackets And Heat Shields


1 - UPPER/LOWER HEAT SHIELDS

2 - TURBOCHARGER SUPPORT BRACKET

3 - ELBOW

4 - ELBOW SUPPORT BRACKET



Fig. 45: Oil Supply Line - Engine Block Fitting


1 - OIL SUPPLY LINE





6 - OIL COOLER COOLANT LINE



Fig. 46: Oil Supply Line - Turbocharger Fitting


OIL RETURN LINE


2. Remove the two fasteners securing the oil return line to the turbocharger.

3. Remove hose clamp from oil return line.

4. Remove oil return line from crankcase nipple. See Fig. 40.

INSTALLATION - LINES AND HOSES

1 - OIL SUPPLY LINE





COOLANT SUPPLY LINE

1. If brass fitting was removed from engine block, apply thread sealer to threads and install in engine block. Torque brass fitting to 41 N.m (30 ft. lbs.).

2. Position coolant supply line to mounting location.

3. Install NEW washers on banjo fitting of coolant supply line. See Fig. 47. Hand start banjo bolt.

4. Hand start flared fitting of coolant supply line.

5. Torque banjo fitting bolt to 30 N.m (22 ft. lbs.). See Fig. 41.

6. Torque flared fitting to 31 N.m (23 ft. lbs.). See Fig. 42.

7. Lower vehicle.


COOLANT RETURN LINE

1. Position coolant return line to mounting location.

2. Install NEW washers on banjo fitting of coolant return line. See Fig. 47. Hand start banjo bolt.

3. Install hose onto heater tube. Install hose clamp. See Fig. 43.

4. Torque banjo fitting bolt to 30 N.m (22 ft. lbs.). See Fig. 41.

5. Install fastener securing coolant return line bracket to cylinder head cover stud. See Fig. 43.

6. Connect charge air cooler hose to throttle body.

7. Tighten hose clamp to 1.7 N.m (15 in. lbs.).

8. Connect Throttle Inlet Pressure (TIP) hose to charge air cooler hose. See Fig. 35.

9. Connect Inlet Air Temperature (IAT) sensor connector. See Fig. 35.



NOTE: For line and hose location, refer to Fig. 40.



Fig. 47: Banjo Bolt And Washers


OIL SUPPLY LINE

1. If brass fitting was removed from engine block or turbocharger, apply thread sealer to threads and install. Torque brass fitting to 41 N.m (30 ft. lbs.).

2. Position oil supply line to mounting location.

3. Hand start flared fitting at turbocharger. See Fig. 46.


5. Hand start flared fitting at engine block. See Fig. 45.

6. Torque flared fittings to 31 N.m (23 ft. lbs.). See Fig. 45 and Fig. 46.

7. Install elbow support bracket. See Fig. 44.

8. Lower vehicle.

1 - BANJO BOLT

2 - WASHERS



OIL RETURN LINE

1. Clean gasket surfaces.

2. Install new gasket.

3. Install oil return line hose over crankcase nipple. See Fig. 40.

4. Install the two fasteners securing the oil return line to the turbocharger. Torque fasteners to 12 N.m (105 in. lbs.).

5. Install hose clamp for oil return line hose.

6. Lower vehicle.

SOLENOIDS AND VACUUM HARNESS

DESCRIPTION

Fig. 48: Vacuum Harness Schematic


Turbocharged vehicles are equipped with three solenoids that are PCM controlled. They are mounted to the right shock tower. A vacuum harness connects the solenoids to their respective component.

� Wastegate Actuator Solenoid

� Surge Valve Actuator Solenoid

NOTE: Refer to Fig. 48 and for component location and vacuum harness routing, see Fig. 49.



� Throttle Inlet Pressure (TIP) Solenoid

REMOVAL

Fig. 49: Turbocharger Solenoids


1. Remove nuts securing solenoid mounting bracket to shock tower. See Fig. 50.

NOTE: For specific solenoid location, refer to Fig. 49.

1 - SPEED CONTROL SERVO

2 - TIP SENSOR

3 - WASTEGATE ACTUATOR SOLENOID

4 - SURGE VALVE ACTUATOR SOLENOID

5 - TIP SOLENOID



2. Disconnect solenoid electrical connector.

3. Disconnect vacuum harness connector from solenoid.

4. Push on solenoid lock tab and slide solenoid off bracket. See Fig. 51.

Fig. 50: Solenoid Mounting Bracket


1 - NUTS



Fig. 51: Solenoid Lock Tab


INSTALLATION

1. Slide solenoid onto mounting bracket until lock tab engages. See Fig. 51.

2. Connect vacuum harness connector to solenoid.

3. Connect solenoid electrical connector.

4. Install nuts securing solenoid mounting bracket to shock tower. See Fig. 50.

© 2008 Mitchell Repair Information Co., LLC.

1 - LOCK TAB



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