Chrysler Front Wheel Drive Cars 4-CYL 1981-1995 Repair Information

Turbocharger/Intercooler

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REMOVAL & INSTALLATION




CAUTION
When draining coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

Many turbocharger failures are due to oil supply problems. Heat soak after hot shutdown can cause the engine oil in the turbocharger and oil lines to "coke.'' Often the oil feed lines will become partially or completely blocked with hardened particles of carbon, blocking oil flow. Check the oil feed pipe and oil return line for clogging. Clean these tubes well. Always use new gaskets above and below the oil feed eyebolt fitting. Do not allow particles of dirt or old gasket material to enter the oil passage hole and that no portion of the new gasket blocks the passage.

1984-85 Models
  1. Disconnect the negative battery cable.
  2.  
  3. Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
  4.  
  5. Drain the cooling system, as described in Routine Maintenanceretdbexz .
  6.  
  7. Disconnect the exhaust pipe at the articulated joint and detach the O 2 sensor electrical connections.
  8.  
  9. Remove the turbocharger-to-block support bracket.
  10.  
  11. Loosen the clamps for the oil drain-back tube, then move the tube downward onto the block fitting so it no longer connects with the turbocharger.
  12.  
  13. Disconnect the turbocharger coolant supply tube at the block outlet below the power steering pump bracket and at the tube support bracket.
  14.  
  15. Disconnect and remove the air cleaner complete with the throttle body adapter, hose, and air cleaner box and support bracket.
  16.  
  17. Loosen the throttle body-to-turbocharger inlet hose clamps. Then, remove the 3 throttle body-to-intake manifold attaching screws and remove the throttle body.
  18.  
  19. Loosen the turbocharger discharge hose end clamps, leaving the center band in place to retain the deswirler.
  20.  
  21. Pull the fuel rail out of the way after removing the hose retaining bracket screw, 4 bracket screws from the intake manifold, and two bracket-to-heat shield retaining clips. The rail, injectors, wiring harness, and fuel lines should be moved as an assembly.
  22.  
  23. Disconnect the oil feed line at the turbocharger bearing housing.
  24.  
  25. Remove the 3 screws attaching the heat shield to the intake manifold and remove the shield.
  26.  
  27. Disconnect the coolant return tube and hose assembly at the turbocharger and water box. Remove the tube support bracket from the cylinder head and remove the assembly.
  28.  
  29. Remove the 4 nuts attaching the turbocharger to the exhaust manifold. Then, remove the turbocharger by lifting it off the exhaust manifold studs, tilting it downward toward the passenger's side of the car, and then pulling it up and out of the engine compartment.
  30.  

To install:
  1. Lower the turbocharger into the engine compartment and position it against the exhaust manifold. When repositioning the turbocharger on the mounting studs, make sure the discharge tube goes in position so that it is properly connected to both the intake manifold and turbocharger. Apply an anti-seize compound such as Loctite® 771-64 or equivalent to the threads. Tighten the nuts to 30 ft. lbs. (41 Nm).
  2.  
  3. Connect the coolant return tube and hose assembly to the turbocharger and water box. Install the tube support bracket onto the cylinder head and tighten the attaching fasteners to 30 ft. lbs. (41 Nm).
  4.  
  5. Install the heat shield to the intake manifold, then install the 3 attaching screws.
  6.  
  7. Connect the oil feed line to the turbocharger bearing housing, then tighten the oil feed line nuts to 125 inch lbs. (14 Nm).
  8.  
  9. Install the fuel rail onto the intake manifold, as described in Fuel System . The fuel rail mounting bolts should be tightened to 21 ft. lbs. (28 Nm).
  10.  
  11. Tighten the turbocharger discharge hose end clamps to 35 inch lbs. (4 Nm).
  12.  
  13. Install the throttle body, then install and tighten the 3 throttle body-to-intake manifold attaching screws to 21 ft. lbs. (28 Nm). Tighten the throttle body-to-turbocharger inlet hose clamps to 35 inch lbs. (4 Nm).
  14.  
  15. Install the air cleaner complete with the throttle body adaptor, hose, and air cleaner box and support bracket. Tighten the hose adapter-to-throttle body screws to 55 inch lbs. (6.2 Nm). Tighten the air cleaner box support bracket bolts to 40 ft. lbs. (54 Nm).
  16.  
  17. Connect the turbocharger coolant supply tube to the engine block outlet below the power steering pump bracket and at the tube support bracket. Tighten the coolant tube nut-to-block fastener to 30 ft. lbs. (41 Nm).
  18.  
  19. Connect the oil drain-back tube to the turbocharger, then tighten the hose clamps.
  20.  
  21. Install the turbocharger-to-engine block support bracket. When installing the turbocharger-to-block support bracket, first install screws finger-tight. Tighten the block screw to 40 ft. lbs. (54 Nm) first, then tighten the screw going into the turbocharger housing to 20 ft. lbs. (27 Nm). Tighten the articulated ball joint shoulder bolts to 21 ft. lbs. (28 Nm).
  22.  
  23. Connect the exhaust pipe to the articulated joint (for more details, refer to the end of this section) and attach the O 2 sensor electrical connections.
  24.  
  25. Fill and bleed the cooling system, as described in Routine Maintenance . Recheck the level after the coolant begins circulating through the radiator, and check for leaks after you install the pressure cap.
  26.  
  27. Lower the vehicle and remove the wheel blocks.
  28.  
  29. Connect the negative battery cable, start the engine and inspect for fluid leaks. Check the turbocharger carefully for any oil leaks and correct if necessary.
  30.  

1986-93 Models

See Figure 1

Click image to see an enlarged view

Fig. Fig. 1: The turbocharger unit removed from the vehicle-2.2L turbo II model's intercooler is an integral part of the turbocharger

The 2.2L Turbo II engine's intercooler is an integral part of the turbocharger unit.

  1. Disconnect the negative battery cable.
  2.  
  3. Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
  4.  
  5. Remove the air cleaner assembly and intake manifold upper plenum-to-cylinder head support bracket.
  6.  
  7. Separate the throttle body assembly from the intake manifold. Detach the EGR tube from the valve.
  8.  
  9. Disengage the PCV, Manifold Absolute Pressure (MAP) and brake booster vacuum supply hoses. Disengage the charge temperature sensor electrical connector.
  10.  
  11. Remove the cowl mounted heat shield and fuel rail, as described in Fuel System .
  12.  
  13. Support the engine from underneath on the oil pan (near the front end of the engine-the pulley end of the engine) with a hydraulic floor jack and a block of wood (to protect the underside of the engine), remove the front engine mount through-bolt and rotate the engine (top) forward and away from the cowl.
  14.  
  15. Unfasten the coolant line where it runs along the water box and turbo housing. Disconnect it at the turbocharger housing and remove the fitting from the turbocharger as well.
  16.  
  17. Disconnect the oil feed line at the turbocharger housing.
  18.  
  19. Remove the wastegate rod-to-gate retaining clip.
  20.  
  21. Remove the 2 upper and 1 lower (driver's side) nuts which retain the turbocharger to the manifold. Disconnect the oxygen sensor electrical lead and vacuum lines.
  22.  
  23. Remove the right side halfshaft, as described in Drive Train .
  24.  
  25. Remove the turbocharger-to-block support bracket. Then, separate the oil drainback tube fitting from the turbocharger housing and remove the fitting and associated hose.
  26.  
  27. Remove the 1 remaining nut retaining the turbocharger to the manifold.
  28.  
  29. Disconnect the articulated exhaust pipe joint from the turbocharger turbine housing outlet.
  30.  
  31. Remove the lower coolant line and the inlet fitting, through which coolant passes into the housing.
  32.  
  33. Lift the turbocharger off the manifold mounting studs and lower it down and out of the vehicle.
  34.  

To install:
  1. Position the turbocharger onto the exhaust manifold. Apply an anti-seize compound such as Loctite 771-64® or equivalent on the threads and install 1 lower retaining nut on the passenger's side, tightening it to 40 ft. lbs. (55 Nm).
  2.  
  3. Apply a thread sealant to the lower coolant inlet line fitting and install the fitting into the turbocharger housing. Connect the lower coolant line.
  4.  
  5. Install a new gasket and install the oil drain-back tube fitting into the turbocharger housing. Connect the coolant line to the fitting.
  6.  
  7. Install the turbocharger-to-block support bracket and install the attaching screws finger tight. First, tighten the block screw to 40 ft. lbs. (55 Nm), then tighten the screw attaching the bracket to the turbocharger housing to 20 ft. lbs. (27 Nm).
  8.  
  9. Reposition the exhaust pipe and connect it to the turbocharger housing outlet. Tighten the attaching bolts to 21 ft. lbs. (28 Nm).
  10.  
  11. Install the right side halfshaft, as described in Drive Train . Install the right side front wheel.
  12.  
  13. Unfasten the coolant line where it runs along the water box and turbo housing. Disconnect it at the turbocharger housing and remove the fitting from the turbocharger as well.
  14.  
  15. Install the remaining 3 turbocharger-to-intake manifold nuts, tightening them to 40 ft. lbs. (54 Nm). Connect the oxygen sensor electrical lead and vacuum lines.
  16.  
  17. Install the wastegate rod-to-gate retaining clip.
  18.  
  19. Connect the oil feed line to the turbocharger housing.
  20.  
  21. In reassembling the front engine mount, align the mount in the crossmember bracket, install the bolt, and tighten it to 40 ft. lbs. (54 Nm).
  22.  
  23. Install the fuel rail. For more information, refer to Fuel System .
  24.  
  25. Install the cowl mounted heat shield.
  26.  
  27. Attach the PCV, Manifold Absolute Pressure (MAP) and brake booster vacuum supply hoses, as well as the charge temperature sensor electrical connector.
  28.  
  29. Install the throttle body assembly on the intake manifold, as described in Fuel System . Install the EGR tube on the valve.
  30.  
  31. Install the air cleaner assembly.
  32.  
  33. Connect the negative battery cable.
  34.  
  35. Start the engine and check for fuel, coolant, oil and vacuum leaks.
  36.  

 
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