Chrysler Le Baron, Dodge Dynasty, Plymouth Acclaim. Manual — part 12

(7) Disconnect Intercooler to throttle body outlet

hose. Disconnect vacuum hoses from throttle body
and remove harness (Fig. 5).

(8) Disconnect automatic idle speed (AIS) motor

and throttle position sensor (TPS) wiring connectors
(Fig. 6).

(9) Remove PCV Breather/Separator box and vac-

uum harness assembly. Remove brake booster, vac-
uum vapor harness and fuel pressure regulator
harness from intake manifold (Fig. 7).

(10) Disconnect Fuel Injector Wiring Connector

(Fig. 8). Charge Temperature Wiring Connector (Fig.
7).

(11) Remove fuel supply and return hose quick

connect at fuel tube assembly (Fig. 9).

WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.

(12) Remove 8 intake manifold screws and washer

assemblies and remove intake manifold (Fig. 10).

INSTALLATION

Before installing manifold. Refer to Cleaning and

Inspection of this section to check manifold for dam-
age.

(1) Install new intake manifold gasket and intake

manifold onto cylinder head and tighten fasteners to
23 N

Im (200 in. lbs.) torque (Fig. 10).

(2) Install PCV Breather/Separator box and vac-

uum harness assembly. Connect brake booster, vac-
uum vapor harness and vacuum hose to fuel pressure
regulator (Fig. 7).

Fig. 1 Air Cleaner and Throttle Body

Assembly—Turbo III Engine

Fig. 2 Radiator to Cylinder Head Hose

Fig. 3 Distributorless Ignition Coil (DIS) Location

Fig. 4 Accelerator and Speed Control Cables

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EXHAUST SYSTEM AND INTAKE MANIFOLD

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(3) Inspect quick connect fittings for damage, re-

place if necessary Refer to Fuel System, Group 14 for
procedure. Lube tube with clean 30w engine oil, Con-
nect fuel supply and return hoses to chassis tube as-
sembly. Check connection by pulling on connector to
insure it locked into position (Fig. 9).

(4) Connect Fuel Injector (Fig. 8), and Charge

Temperature Sensor wiring connectors (Fig. 7).

INTAKE MANIFOLD

(5) Connect Automatic Idle Speed (AIS) and Throt-

tle Position Sensor (TPS) wiring connectors (Fig. 6).

(6) Connect vacuum hoses to throttle body (Fig. 5).
(7) Install intercooler to throttle body hose and

clamp. Torque clamp to 3 N

Im (30 in. lbs.) (Fig. 5).

(8) Connect accelerator and speed control cables

(Fig. 4).

(9) Install DIS ignition coil pack. Tighten fasteners

to 12 N

Im (105 in. lbs.) torque (Fig. 3).

(10) Install upper radiator hose and spring clamps

(Fig. 2). Fill cooling system, Refer to Cooling System,
Group 7.

(11) Install fresh air duct to air filter housing. In-

stall inlet hose assembly to Intercooler. Tighten
clamp to 3 N

Im (30 in. lbs.) torque (Fig. 1).

(12) Connect negative battery cable.
(13) With the DRBII Scan Tool use ASD Fuel Sys-

tem Test to pressurize system to check for leaks.

Fig. 5 Intercooler to Throttle Body Hose

Fig. 6 Automatic Idle Speed (AIS) Motor and

Throttle Position Sensor (TPS) Wiring Connectors

Fig. 7 Intake Manifold Electrical and Vacuum Hose

Connections

Fig. 8 Camshaft Sensor and Fuel Injectors Wiring

Connectors

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EXHAUST SYSTEM AND INTAKE MANIFOLD

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CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) relay will remain ener-
gized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is se-
lected.

TURBOCHARGER

REMOVAL

The turbocharger is removed from below the vehi-

cle. Cylinder head removal for component accessibil-
ity is not required.

(1) Disconnect negative battery cable. Remove Air

Cleaner assembly (Fig. 1).

(2) From Above: Remove front engine mount

through bolt and rotate engine (Top) forward away
from cowl. Refer to Engine Removal in Engine,
Group 9.

(3) Remove Air Cleaner Support (Fig. 1).
(4) Disconnect Heated Oxygen sensor lead wire

and vacuum lines.

(5) Separate coolant return line from water box

and turbocharger housing (Fig. 11). Remove return
line from turbocharger.

(6) Separate oil feed line from turbocharger hous-

ing (Fig. 12).

(7) Remove three (two upper and one lower driver’s

side) nuts retaining turbocharger to manifold (Fig.
12).

(8) From Below: Remove right front wheel and

tire assembly.

(9) See Suspension, Group 2, and remove right

driveshaft assembly.

Air deflector may need to be removed from cross-

member.

(10) Separate oil drain back tube fitting from tur-

bocharger housing and remove fitting and hose (Fig.
13).

(11) Remove turbocharger to block support bracket

(Fig. 13).

(12) Remove one remaining turbocharger to mani-

fold retaining nut (Fig. 12).

Fig. 11 Coolant Tube Routing

Fig. 12 Turbocharger Attaching Nuts

Fig. 9 Fuel Supply and Return Hose Connections

Fig. 10 Intake Manifold Attaching Bolts.

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EXHAUST SYSTEM AND INTAKE MANIFOLD

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(13) Disconnect articulated exhaust pipe joint from

turbocharger housing.

(14) Remove turbocharger coolant inlet line assem-

bly from engine (Fig. 11).

(15) Lift turbocharger off manifold mounting studs

and lower assembly down and out of vehicle.

EXHAUST MANIFOLD

REMOVAL

Remove 9 exhaust manifold retaining fasteners and

remove exhaust manifold (Fig. 14).

CLEANING AND INSPECTION

(1) Discard gasket and clean all gasket surfaces of

manifolds and cylinder head.

(2) Test manifold gasket surfaces for flatness with

straight edge. Surface must be flat within 0.15 mm
per 300 mm (.006 in. per foot) of manifold length.

(3) Inspect manifolds for cracks or distortion. Re-

place manifold if necessary.

EXHAUST MANIFOLD

INSTALLATION

(1) Install new manifold gasket. DO NOT APPLY

SEALER.

(2) Set exhaust manifold in place. Tighten retain-

ing nuts and bolt, starting at center and progressing
outward in both directions to 23 N

Im (200 in. lbs.)

torque. Repeat this procedure until all fasteners are
at specified torque (Fig. 14).

TURBOCHARGER

INSTALLATION

(1) Position turbocharger on exhaust manifold. Ap-

ply antiseize compound to threads and install the
lower

(passenger

side)

retaining

nut

(Fig.

12).

Tighten nut to 54 N

Im (40 ft. lbs.) torque.

(2) Apply thread sealant to lower (inlet) coolant

line fitting and install fitting into turbocharger hous-
ing (Fig. 11).

(3) Install lower coolant line assembly to engine

(Fig. 11).

(4) Install oil drain back tube and fitting (with

new gasket) to turbocharger housing (Fig. 13).

(5) Install turbocharger to block support bracket

and install screws finger tight (Fig. 13). Tighten
block screw FIRST to 54 N

Im (40 ft. lbs.) torque,

then tighten screw to turbocharger housing to 27
N

Im (20 ft. lbs.) torque.

(6) Reposition exhaust pipe. Tighten articulated

joint shoulder bolts to 28 N

Im (250 in. lbs.) torque.

(7) See Suspension, Group 2, and install right

driveshaft and wheel and tire assembly. Install air
deflector on crossmember.

(8)

From Above: Install three turbocharger to

manifold retaining nuts. Tighten to 54 N

Im (40 ft.

lbs.) torque (Fig. 12).

(9) Reconnect Heated Oxygen sensor electrical con-

nection and vacuum lines.

(10) Attach oil feed line to turbocharger bearing

housing. Tighten fitting to 14 N

Im (125 in. lbs.)

torque (Fig. 12).

(11) Install coolant line and tighten fittings to 41

N

Im (30 ft. lbs.) torque (Fig. 11).

(12) Install air cleaner support (Fig. 1).
(13) Align front engine mount in crossmember

bracket. Install through bolt and tighten to 54 N

Im

(40 ft. lbs.) torque.

(14) Install air cleaner assembly (Fig. 1).
(15) Fill cooling system. Refer to Cooling System,

Group 7 for procedure.

INTAKE/EXHAUST MANIFOLD SERVICE—3.0L
ENGINE

The intake system has a large air intake plenum of

aluminum alloy and a cross type intake manifold
(Fig. 2).

Fig. 13 Oil Return Tube and Support Bracket

Fig. 14 Exhaust Manifold—Turbo III Engine

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EXHAUST SYSTEM AND INTAKE MANIFOLD

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