Exhaust System: Turbocharger: Installation

Fig 1: Removing/Installing Turbo, Shields, Exhaust System, Support Brackets Components

Courtesy of DAIMLERCHRYSLER CORP.

1. Reconnect turbo boost pressure servo connector (2). See Fig 1.
2. Position and install the turbocharger on the exhaust manifold, tighten the retainers to 30N.m (22 lbs.ft.).
   CAUTION: Make sure the gasket is installed properly or the turbo oil feed hole will be blocked.
3. Install front turbo retaining bolts and gasket and install turbo (1).
   Fig 2: Removing/Installing Air Intake, Turbo, Exhaust System Components

   Courtesy of DAIMLERCHRYSLER CORP.
4. Install left and right exhaust manifold retaining bolts and gaskets (4). See Fig 2.
5. Reconnect EGR tube at manifold to left cylinder head (3).
6. Reconnect EGR tube at manifold to left cylinder head (3).
7. Reconnect transmission fill tube and trim cover bracket and set aside.
8. Install upstream catalytic converter.
9. Raise vehicle and reconnect catalytic converter to downstream catalytic converter clamp.
10. Install extension pipe and catalytic converter.
11. Reconnect O2 sensor wire connector.
12. Reconnect the extension pipe to muffler.
13. Reconnect the downstream catalytic converter at the extension pipe.
14. Refill cooling system (Refer to STANDARD PROCEDURE ).
15. Lower vehicle, install the turbo front bracket retaining bolts (2).
    Fig 3: Removing/Installing Air Intake, Turbo, Exhaust System Components

    Courtesy of DAIMLERCHRYSLER CORP.
16. Install the exhaust clamp (elbow to converter) (1). See Fig 3.
    Fig 4: Installing Turbo Shield

    Courtesy of DAIMLERCHRYSLER CORP.
17. Install the turbo heat shield (4). See Fig 4.
18. Install air tube (turbo to cooler) (3).
19. Install engine cover front bracket (2).
20. Install air intake tube (air cleaner to turbo) (1).
21. Install the engine trim cover.
22. Reconnect negative battery cable.