Neon, 2000-2005

Turbocharger

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Removal & Installation



2.4L Engine

WARNING
If the turbocharger is replaced due to a bearing failure, you must also replace the oil pressure feed line. The oil return tube should also be cleaned.


NOTE
The turbocharger and exhaust manifold are serviced as an assembly. Do NOT try to separate the turbocharger from the exhaust manifold. This will cause exhaust leaks. Chrysler recommends that the turbocharger elbow be replaced along with the turbocharger/exhaust manifold assembly.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner housing and lid
     
    Clean air hose from turbocharger
     
    Throttle and speed control cables from the throttle body
     

  6.  
  7. Disconnect the electrical connectors from the following components:
    NOTE
    Cover the openings in the manifold to prevent debris from entering.



    Inlet Air Temperature (IAT) Sensor
     
    Manifold Absolute Pressure (MAP) Sensor
     
    Idle Air Control (IAC) Motor
     
    Throttle Position Sensor (TPS)
     
    Ignition Coil Capacitor
     
    Upstream Oxygen Sensor (O 2 S)
     
    Air inlet hose from the throttle body
     
    Vacuum hoses from the throttle body and upper intake manifold
     
    Upper intake manifold support bracket and upper intake manifold
     



    Turbocharger upper heat shield
     
    Oil supply line from the turbocharger
     
    Coolant return line
     
    Vacuum hoses from the turbocharger
     
    Muffler ground strap and muffler
     
    Downstream O 2 S
     
    Fasteners securing the catalytic converter to the exhaust manifold
     
    Catalytic converter and intermediate pipe as an assembly
     
    Turbocharger to charge air cooler hose assembly
     
    Turbocharger elbow support bracket
     
    Turbocharger support bracket
     
    Oil return tube
     
    Turbocharger coolant supply line
     
    Turbocharger lower heat shield
     
    Turbocharger elbow
     
    Lower exhaust manifold fasteners that are accessible while vehicle raised
     
    Upper exhaust manifold fasteners
     
    Turbocharger/exhaust manifold assembly from above/between the engine and cowl panel. Discard the gasket
     

  8.  
  9. Inspect the turbocharger assembly for cracks and other damage and replace if necessary.

    Click image to see an enlarged view

    Fig. Clean air hose-2.4L engine

    Clean air hose-2.4L engine

    Click image to see an enlarged view

    Fig. Charge air cooler hoses-2.4L engine

    Charge air cooler hoses-2.4L engine

    Click image to see an enlarged view

    Fig. Support bracket mounting-2.4L engine

    Support bracket mounting-2.4L engine

    Click image to see an enlarged view

    Fig. Turbocharger lines and hoses-2.4L engine

    Turbocharger lines and hoses-2.4L engine

    Click image to see an enlarged view

    Fig. Converter-to-exhaust manifold attachment-2.4L engine

    Converter-to-exhaust manifold attachment-2.4L engine

    Click image to see an enlarged view

    Fig. Charge air cooler hose-2.4L engine

    Charge air cooler hose-2.4L engine

    Click image to see an enlarged view

    Fig. Turbocharger heat shield mounting-2.4L engine

    Turbocharger heat shield mounting-2.4L engine
  10.  

To install:

  1. Install or connect the following:
    NOTE
    The lower turbocharger heat shield tabs must overlap the upper heat shield tabs to prevent fatiguing and early failure.



    New gasket. The stainless steel layer of the exhaust manifold gasket goes against the cylinder head, and the graphite layer of the gasket goes against the manifold surface.
     
    Turbocharger/exhaust manifold assembly in place, from between the engine and brake master cylinder. Gradually tighten the fasteners, starting at the center and going outward in both directions to 21 ft. lbs. (28 Nm). You will need to raise and lower the vehicle for fastener access as necessary.
     
    Alternator heat shield
     
    Coolant return line, using new washers. Tighten the banjo fitting bolt to 27 ft. lbs. (37 Nm)
     
    Turbocharger coolant supply line, using new washers. Tighten the banjo fitting bolt to 27 ft. lbs. (37 Nm). Torque the flared fitting to 23 ft. lbs. (31 Nm).
     
    Turbocharger elbow and tighten the fasteners to 21 ft. lbs. (28 Nm)
     
    Turbocharger upper heat shield and fasteners, loosely.
     
    Turbocharger support bracket. Torque the M8 fasteners to 21 ft. lbs. (28 Nm) and the M10 fasteners to 40 ft. lbs. (54 Nm).
     
    Oil return tube with a new gasket. Tighten the fasteners to 105 inch lbs. (12 Nm). Make sure heat shield for oil return line is properly installed.
     
    Turbocharger elbow support bracket
     
    Turbocharger-to-charge air cooler hose assembly
     
    Catalytic converter with new gasket. Tighten the converter-to-manifold fasteners to 21 ft. lbs. (28 Nm).
     
    Downstream O 2 S
     
    Exhaust extension pipe to catalytic converter
     
    Power steering cooler fasteners
     
    Oil supply line to the turbocharger with new washers. Tighten the banjo fitting bolt to 27 ft. lbs. (37 Nm).
     



    Turbocharger lower heat shield. Torque the upper and lower heat shield fasteners to 21 ft. lbs. (28 Nm)
     
    Vacuum hoses to turbocharger
     
    Upstream O 2 S
     
    Ignition coil and electrical connector
     
    Electrical connector into bracket
     
    Clean air hose
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system
  4.  
  5. Change the oil and filter.
  6.  
  7. Start the engine and check for exhaust leaks. Repair leaks as necessary.
  8.  
  9. Inspect the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.
  10.  

 
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