PT Cruiser L4-2.4L Turbo VIN G (2004)
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.
INSTALLATION
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 turbochargerlexhaust manifold assembly.
1. Clean gasket sealing surfaces. Replace exhaust manifold gasket. DO NOT APPLY SEALER TO GASKET.
NOTE: Stainless steel layer of exhaust manifold gasket goes against cylinder head, graphite layer of gasket goes against manifold surface.
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 center and progressing outward in both
directions to 28 Nm (250 in. lbs.). Raise and lower vehicle for fastener access as necessary Repeat tightening procedure until all fasteners are at
specified torque.
4. Install turbocharger elbow. Torque fasteners to 28 Nm (250 in. lbs.).
5. Install turbocharger lower heat shield. Torque fasteners to 28 Nm (250 in. lbs.).
6. Install turbocharger coolant supply line. Install NEW washers. Torque banjo fitting bolt to 30 Nm (22 ft. lbs.). Torque flared fitting to 31 Nm (23
ft. lbs.).
7. Replace oil return tube gasket. Install oil return tube. Torque fasteners to 12 Nm (105 in. lbs.). Make sure heat shield for oil return line is properly
installed.
8. Install turbocharger support bracket. Torque M8 fasteners to 28 Nm (250 in. lbs.) and M10 fasteners to 54 Nm (40 ft. lbs.).
9. Install turbocharger elbow support bracket.
10. Install turbocharger to charge air cooler hose assembly.
11. Install catalytic converter and intermediate pipe as an assembly.
12. Install fasteners securing catalytic converter to exhaust manifold. Torque fasteners to 28 Nm (250 in. lbs.).
13. Install muffler. Connect muffler ground strap.
14. Connect downstream oxygen sensor.
15. Lower vehicle.
16. Connect vacuum hoses to turbocharger.
