The turbocharger is a precision component that has been assembled and balanced to very fine tolerances; do not disassemble or attempt to repair it, as only authorized turbocharger repair facilities should perform overhauls or repairs. An incorrectly assembled turbocharger could lead to damage to both the turbocharger and the engine. To remove the turbocharger, first disconnect the cable from the negative terminal of the battery, drain the cooling system, and remove the air filter housing. Loosen the hose clamp and disconnect the clean air intake duct from the turbocharger, then disconnect the accelerator cable and cruise control cable from the throttle lever. Disconnect the electrical connectors from the Intake Air Temperature sensor, the Manifold Absolute Pressure sensor, the Idle Air Control motor, the Throttle Position sensor, and the upstream oxygen sensor, as well as the electrical connector from the ignition coil capacitor. Disconnect the air intake duct at the throttle body, label and disconnect the vacuum hoses from the throttle body and intake manifold, and remove the upper intake manifold support bracket. Cover the intake passages in the lower half of the intake manifold to prevent dirt and debris from entering the engine, then remove the upper turbocharger heat shield, disconnect the oil supply line and coolant return line, and label and disconnect the vacuum hoses from the turbocharger assembly. Raise the vehicle securely on jackstands, disconnect the muffler ground strap, and remove the muffler. Disconnect the electrical connector from the downstream oxygen sensor, remove the nuts attaching the catalytic converter to the exhaust manifold flange, and remove the catalytic converter and intermediate pipe as a single assembly. Remove the turbocharger-to-charge air cooler duct, the turbocharger elbow support bracket, and the turbocharger support bracket, followed by the oil return line and the turbocharger coolant supply line. Remove the lower turbocharger heat shield, the turbocharger elbow, and the four lower exhaust manifold fasteners, then lower the vehicle and remove the six upper exhaust manifold fasteners. Finally, remove the turbocharger/exhaust manifold assembly from above, between the engine and the firewall, and discard the old exhaust manifold gasket. For installation, clean the oil return tube and consider replacing the oil pressure feed line; install a new gasket, position the turbocharger/exhaust manifold assembly, install the fasteners, and gradually and evenly tighten them to the specified torque, starting at the center and working outward. The remainder of the installation follows the reverse order of removal, and refill and bleed the cooling system afterward.
Posted by MoparPartsGiant Specialist 
