PT Cruiser 2006-2007

Turbocharger

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    The exhaust manifold on turbocharged models is removed as an assembly with the turbocharger. Do not remove the turbocharger from the manifold. Always replace the turbocharger as a complete assembly.


    CAUTION
    If the turbocharger is being replaced due to bearing failure, the oil pressure feed line has to be replaced and the return tube should be cleaned.

  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Cover the lower intake manifold to avoid dirt and other objects from entering.



    The negative battery cable
     
    The air cleaner housing
     
    The clean air hose from the turbocharger
     
    The throttle and cruise control cables from the throttle lever bracket
     
    The Inlet Air Temperature (IAT) sensor
     
    The Manifold Absolute Pressure (MAP) sensor
     
    The Idle Air Control (IAC) motor electrical connector
     
    The Throttle Position Sensor (TPS) wiring connector
     
    The ignition coil capacitor
     
    The upstream Oxygen Sensor (O 2 S) connector
     
    The air inlet hose from the throttle body
     
    The vacuum hoses from the throttle body and upper intake manifold
     
    The upper intake manifold support bracket and manifold
     



    The turbocharger lower heat shield
     
    The oil supply line from the turbocharger
     
    The coolant return line
     
    The vacuum hoses
     
    The muffler ground strap
     
    The downstream O 2 S connector
     
    The catalytic converter and intermediate pipe as an assembly
     
    The turbocharger to charge air cooler hose assembly
     
    The turbocharger, elbow support and support brackets
     
    The oil return tube
     
    The turbocharger coolant supply line and upper heat shield
     
    The turbocharger elbow
     
    The lower exhaust manifold fasteners from below, then lower the vehicle and remove the upper manifold fasteners
     
    The turbocharger/manifold assembly from between the engine and cowl panel.
     

  6.  
  7. Discard the gasket.
  8.  
  9. Clean the mating surfaces.

    Click image to see an enlarged view

    Fig. Charge air cooler hoses-Turbo models



    Click image to see an enlarged view

    Fig. Turbocharger line and hose locations-Turbo models



    Click image to see an enlarged view

    Fig. Turbocharger bracket and heat shield locations-Turbo models



    Click image to see an enlarged view

    Fig. Exhaust manifold torque sequence-Turbo models

  10.  

To install:

  1. Install or connect the following:
    NOTE
    The lower heat shield tabs must overlap the upper heat shield to prevent fatigue and premature union failure.



    The new gasket. Use no sealer when installing the gasket
     
    The turbocharger/manifold assembly between the engine and cowl panel. Tighten the fasteners working from the center out in progressing in both directions to 21 ft. lbs. (28 Nm)
     
    The turbocharger elbow. Tighten the fasteners to 21 ft. lbs. (28 Nm).
     
    The turbocharger upper heat shield. Tighten the fasteners to 21 ft. lbs. (28 Nm).
     
    The coolant supply line using new washers. Tighten the banjo bolt to 22 ft. lbs. (30 Nm) and the flared fitting to 23 ft. lbs. (31 Nm).
     
    The new oil return tube gasket, return tub and tighten to 105 inch lbs. (12 Nm). Make sure the heat shield for the oil return line is installed properly.
     
    The turbocharger support bracket. Tighten the M8 fasteners to 21 ft. lbs. (28 Nm) and the M10 fasteners to 40 ft. lbs. (54 Nm).
     
    The turbocharger elbow support bracket
     
    The turbocharger to charge air cooler hose assembly
     
    The catalytic converter and intermediate pipe as an assembly
     
    The muffler ground strap
     
    The downstream O 2 S connector
     
    The vacuum hose
     
    The coolant return line using new washers. Tighten the banjo bolt to 22 ft. lbs. (30 Nm)
     
    The oil supply line and tighten the flared fitting to 23 ft. lbs. (31 Nm)
     



    The turbocharger lower heat shield. Tighten the fasteners to 21 ft. lbs. (28 Nm)
     

  2.  
  3. Remove the cover placed on the lower intake manifold.

    The upper intake manifold and support bracket
     
    The vacuum hoses to the throttle body and upper intake manifold
     
    The air inlet hose to the throttle body
     
    The IAT sensor connector
     
    The MAP sensor
     
    The TPS sensor wiring connector
     
    The IAC motor electrical connector
     
    The ignition coil capacitor
     
    The upstream O 2 S connector
     
    The throttle and cruise control cables to the throttle lever bracket
     
    The clean air hose to the turbocharger
     
    The air cleaner housing
     
    The negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Chain the oil and filter.
  8.  
  9. Start the vehicle and check for exhaust system leaks and also check the system is not contacting any body panels. Adjust the system as necessary to avoid panel contact.
  10.  

 
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