Liberty, Wrangler, 1997-2005

Turbocharger

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Removal & Installation



2.8L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect negative battery cable.
  4.  
  5. Remove engine cover.
  6.  
  7. Disconnect the MAF and Inlet air pressure sensors wiring harness connectors, disconnect the air outlet duct from the turbocharger, and remove air cleaner assembly.
  8.  
  9. Remove charge air cooler outlet hose from turbocharger.
  10.  
  11. Drain cooling system.
  12.  
  13. Remove coolant reservoir.
  14.  
  15. Disconnect the turbocharger actuator vacuum hose and position aside.
  16.  
  17. Remove turbocharger upper heat shield.
  18.  
  19. Raise and support the vehicle.
  20.  
  21. Remove the lower splash shield.
  22.  
  23. Disconnect the front exhaust pipe from the turbocharger.
  24.  
  25. Remove the turbocharger support bracket.
  26.  
  27. Disconnect turbocharger oil return line at turbocharger.
  28.  
  29. Lower the vehicle.
  30.  
  31. Remove the turbocharger oil supply line.
  32.  
  33. Remove turbocharger to exhaust manifold retaining nuts and separate turbocharger from exhaust manifold.

    Click image to see an enlarged view

    Fig. Turbocharger and oil lines-2.8L diesel engine

  34.  

To install:

  1. 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.

  2.  
  3. Tighten the exhaust manifold to cylinder head fasteners in a diagonal-cross pattern to 26 ft. lbs. (36 Nm).
  4.  
  5. Connect turbocharger to exhaust manifold with new gasket. Torque retaining nuts to 32 Nm.
  6.  
  7. Connect oil supply line at turbocharger. Torque banjo fitting to 18 ft. lbs. (24 Nm).
  8.  
  9. Raise and support the vehicle.
  10.  
  11. Connect the oil return pipe to the turbocharger with new gasket and tighten the fasteners to 95 inch lbs. (10 Nm).
  12.  
  13. Install the turbocharger support bracket and tighten fasteners to 18 ft. lbs. (24 Nm).
  14.  
  15. Connect the front exhaust pipe to the turbocharger.
  16.  
  17. Install the lower skid plate.
  18.  
  19. Lower the vehicle.
  20.  
  21. Install the upper turbocharger heat shield. Tighten the fasteners to 18 ft. lbs. (24 Nm).
  22.  
  23. Connect the turbocharger actuator vacuum hose to the actuator.
  24.  
  25. Install the coolant reservoir.
  26.  
  27. Install the charge air outlet hose
  28.  
  29. Install the air cleaner assembly and connect the electrical connectors.
  30.  
  31. Install engine cover.
  32.  
  33. Refill cooling system.
  34.  
  35. Connect negative battery cable.
  36.  

 
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