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2007 dodge caliber Turbocharger removal?

The procedure to replace Turbocharger.
The how to replace turbocharger procedure.
In this chapter complete details are provided to remove/ install turbocharger.


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 turbocharger/exhaust manifold assembly.

  1. Disconnect negative battery cable.
  2. Drain cooling system.
  3. Remove air cleaner housing and lid.
  4. Disconnect clean air hose from turbocharger.
  5. Disconnect throttle and speed control cables at throttle body.
  6. Disconnect electrical connectors from the following components:

    Inlet Air Temperature (IAT) Sensor
    MAP Sensor
    IAC Motor
    Throttle Position Sensor
    Ignition Coil Capacitor
    Upstream Oxygen Sensor
  7. Disconnect air inlet hose at throttle body.
  8. Disconnect vacuum hoses at throttle body and upper intake manifold.
  9. Remove upper intake manifold support bracket.
  10. Remove upper intake manifold.
    CAUTION
    Cover lower intake manifold opening with suitable cover to prevent any foreign objects from entering.
  11. Disconnect oil supply line at turbocharger.
  12. Remove coolant return line.
  13. Disconnect vacuum hoses from turbocharger.
  14. Raise vehicle on hoist.
  15. Disconnect muffler ground strap. Remove muffler.
  16. Disconnect downstream oxygen sensor.
  17. Remove fasteners securing catalytic converter to exhaust manifold.
  18. Remove catalytic converter and intermediate pipe as an assembly.
  19. Remove turbocharger to charge air cooler hose assembly.
  20. Remove turbocharger lower heat shield.
  21. Remove turbocharger elbow support bracket.
  22. Remove turbocharger support bracket.
  23. Remove turbocharger elbow.
  24. Remove lower exhaust manifold fasteners that are accessible while vehicle is on hoist.
  25. Lower vehicle.
  26. Remove upper exhaust manifold fasteners.
  27. Remove turbocharger/exhaust manifold assembly from above/between the engine and cowl panel.
  28. Remove and discard exhaust manifold gasket.
To install:

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 turbocharger/exhaust 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 21 ft. lbs. (28 Nm). Raise and lower vehicle for fastener access as necessary. Repeat tightening procedure until all fasteners are at specified torque..
  4. Install turbocharger elbow. Tighten fasteners to 21 ft. lbs. (28 Nm.).
  5. Install turbocharger upper heat shield. Tighten fasteners to 21 ft. lbs. (28 Nm.).
  6. Install turbocharger coolant supply line. Install NEW washers. Tighten banjo fitting bolt to 27 ft. lbs. 37 Nm.). Tighten flared fitting to 23 ft. lbs. (31 Nm).
  7. Replace oil return tube gasket. Install oil return tube. Tighten fasteners to 105 inch lbs. (12 Nm). Make sure heat shield for oil return line is properly installed.
  8. Install turbocharger support bracket. Tighten M8 fasteners to 21 ft. lbs. (28 Nm.) and M10 fasteners to 54 N·m (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. Tighten fasteners to 21 ft. lbs. (28 Nm.).
  13. Install muffler. Connect muffler ground strap.
  14. Connect downstream oxygen sensor.
  15. Lower vehicle.
  16. Connect vacuum hoses to turbocharger.
  17. Install coolant return line. Install NEW washers. Tighten banjo fitting bolt to 27 ft. lbs. (37 Nm.).
  18. Connect oil supply line at turbocharger. Tighten flared fitting to 23 ft. lbs. (31 Nm).
    NOTE
    The lower heat shield tabs must overlap the upper heat shield to prevent fatiguing and premature failure of the union.
  19. Install turbocharger lower heat shield. Tighten fasteners to 21 ft. lbs. (28 Nm).
  20. Install upper intake manifold.
  21. Install upper intake manifold support bracket.
  22. Connect vacuum hoses at throttle body and upper intake manifold.
  23. Connect air inlet hose at throttle body.
  24. Connect electrical connectors to the following components:

    Inlet Air Temperature (IAT) Sensor
    MAP Sensor
    IAC Motor
    Throttle Position Sensor
    Ignition Coil Capacitor
    Upstream Oxygen Sensor
  25. Connect throttle and speed control cables at throttle body.
  26. Connect clean air hose to turbocharger.
  27. Install air cleaner housing and lid.
  28. Fill cooling system.
  29. Change oil and filter.
  30. Connect negative battery cable.
  31. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
  32. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.

These details will help.
Thanks.           

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html



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