Dodge Neon / Neon SRT-4. Manual — part 270
(6) Disconnect electrical connectors from the fol-
lowing 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 (Fig.
6).
(8) Disconnect vacuum hoses at throttle body and
upper intake manifold.
(9) Remove upper intake manifold support bracket
(Fig. 7).
(10) Remove upper intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE
MANIFOLD
-
REMOVAL).
CAUTION: Cover lower intake manifold opening
with suitable cover to prevent any foreign objects
from entering.
(11) Remove turbocharger upper heat shield (Fig.
11).
(12) Disconnect oil supply line at turbocharger
(Fig. 8).
(13) Remove coolant return line (Fig. 8).
(14) Disconnect vacuum hoses from turbocharger.
(15) Raise vehicle on hoist.
(16) Disconnect muffler ground strap. Remove
muffler (Refer to 11 - EXHAUST SYSTEM/MUF-
FLER - REMOVAL).
Fig. 5 Clean Air Hose - 2.4L Turbo
1 - CLEAN AIR HOSE
2 - TURBOCHARGER
Fig. 6 Charge Air Cooler Hoses
1 - HOSE - CHARGE AIR COOLER TO THROTTLE BODY
2 - CHARGE AIR COOLER
3 - HOSE - TURBOCHARGER TO CHARGE AIR COOLER
Fig. 7 Support Bracket
1 - FASTENERS
2 - UPPER INTAKE MANIFOLD SUPPORT BRACKET
11 - 6
EXHAUST SYSTEM AND TURBOCHARGER
PL/SRT-4
TURBOCHARGER (Continued)
(17) Disconnect downstream oxygen sensor.
(18) Remove fasteners securing catalytic converter
to exhaust manifold (Fig. 9).
(19) Remove catalytic converter and intermediate
pipe as an assembly.
(20) Remove turbocharger to charge air cooler hose
assembly (Fig. 10).
(21) Remove turbocharger elbow support bracket
(Fig. 11).
(22) Remove turbocharger support bracket (Fig.
11).
(23) Remove oil return tube (Fig. 8).
(24) Remove turbocharger coolant supply line (Fig.
8).
(25) Remove turbocharger lower heat shield (Fig.
8).
(26) Remove turbocharger elbow (Fig. 11).
(27) Remove lower exhaust manifold fasteners that
are accessible while vehicle is on hoist.
(28) Lower vehicle.
(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.
Fig. 8 Turbocharger Lines and Hoses
1 - OIL SUPPLY LINE
2 - COOLANT RETURN LINE
3 - COOLANT SUPPLY LINE
4 - OIL RETURN TUBE
Fig. 9 Converter to Exhaust Manifold Connection -
2.4L Turbo
1 - FLAG NUT
2 - GASKET
3 - NUT
4 - BOLT
5 - CATALYTIC CONVERTER
Fig. 10 Charge Air Cooler Hose
1 - CHARGE AIR COOLER
2 - HOSE - TURBOCHARGER TO CHARGE AIR COOLER
3 - NUT
PL/SRT-4
EXHAUST SYSTEM AND TURBOCHARGER
11 - 7
TURBOCHARGER (Continued)
INSPECTION - TYPICAL TURBOCHARGER
Visually inspect the turbocharger and exhaust
manifold gasket surfaces. Replace stripped or eroded
mounting studs.
(1) Visually inspect the turbocharger for cracks.
The following cracks are NOT acceptable:
• Cracks in the turbine and compressor housing
that go completely through.
• Cracks in the mounting flange that are longer
than 15 mm (0.6 in.).
• Cracks in the mounting flange that intersect
bolt through-holes.
• Two (2) Cracks in the mounting flange that are
closer than 6.4 mm (0.25 in.) together.
(2) Visually inspect the impeller and compressor
wheel fins for nicks, cracks, or chips.
(3) Visually inspect the turbocharger compressor
housing for an impeller rubbing condition (Fig. 12).
Replace the turbocharger if the condition exists.
(4) Measure the turbocharger axial end play:
(a) Install a dial indicator. Zero the indicator at
one end of travel.
(b) Move the impeller shaft fore and aft and
record the measurement. Allowable end play is
0.038 mm (0.0015 in.) MIN. and 0.089 mm (0.0035
in.) MAX. If the recorded measurement falls out-
side these parameters, replace the turbocharger
assembly.
(5) Measure the turbocharger bearing radial clear-
ance:
(a) Insert a narrow blade or wire style feeler
gauge between the compressor wheel and the hous-
ing.
(b) Gently push the compressor wheel toward
the housing and record the clearance.
(c) With the feeler gauge in the same location,
gently push the compressor wheel away from the
housing and again record the clearance.
(d) Subtract the smaller clearance from the
larger clearance. This is the radial bearing clear-
ance.
(e) Allowable radial bearing clearance is 0.326
mm (0.0128 in.) MIN. and 0.496 mm (0.0195 in.)
MAX. If the recorded measurement falls outside
these
specifications,
replace
the
turbocharger
assembly.
INSTALLATION - TURBOCHARGER
CAUTION: IF TURBOCHARGER IS REPLACED DUE
TO A BEARING FAILURE, REPLACEMENT OF THE
OIL PRESSURE SUPPLY LINE IS REQUIRED. OIL
RETURN TUBE SHOULD ALSO BE CLEANED.
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.
Fig. 11 Turbocharger Brackets and Heat Shields
1 - UPPER/LOWER HEAT SHIELDS
2 - TURBOCHARGER SUPPORT BRACKET
3 - ELBOW
4 - ELBOW SUPPORT BRACKET
Fig. 12 Inspect Compressor Housing for Impeller
Rubbing Condition
11 - 8
EXHAUST SYSTEM AND TURBOCHARGER
PL/SRT-4
TURBOCHARGER (Continued)
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 between the engine and brake master
cylinder (Fig. 9).
(3) Position turbocharger/exhaust manifold assem-
bly in place. Gradually tighten fasteners, starting at
center and progressing outward in both directions to
28 N·m (250 in. lbs.) (Fig. 13). Raise and lower vehi-
cle for fastener access as necessary. Repeat tighten-
ing procedure until all fasteners are at specified
torque.
(4) Install generator heat shield.
(5) Install coolant return line. Install NEW wash-
ers (Fig. 14). Torque banjo fitting bolt to 37 N·m (27
ft. lbs.) (Fig. 8).
(6) Install turbocharger coolant supply line. Install
NEW washers (Fig. 14). Torque banjo fitting bolt to
37 N·m (27 ft. lbs.). Torque flared fitting to 31 N·m
(23 ft. lbs.) (Fig. 8).
(7) Install turbocharger elbow. Torque fasteners to
28 N·m (250 in. lbs.) (Fig. 11).
(8) Loosely install turbocharger upper heat shield
and fasteners (Fig. 11).
(9) Install turbocharger support bracket. Torque
M8 fasteners to 28 N·m (250 in. lbs.) and M10 fas-
teners to 54 N·m (40 ft. lbs.) (Fig. 11).
(10) Replace oil return tube gasket. Install oil
return tube. Torque fasteners to 12 N·m (105 in. lbs.).
Make sure heat shield for oil return line is properly
installed (Fig. 8).
(11) Install turbocharger elbow support bracket
(Fig. 11).
(12) Install turbocharger to charge air cooler hose
assembly (Fig. 10).
(13) Install catalytic converter with new gasket.
(14) Install fasteners securing catalytic converter
to exhaust manifold (Fig. 9). Torque fasteners to 28
N·m (250 in. lbs.).
(15) Connect downstream oxygen sensor.
(16) Connect exhaust extension pipe to catalytic
converter.
(17) Install power steering cooler fasteners.
(18) Lower vehicle.
(19) Connect
oil
supply
line
at
turbocharger.
Install NEW washers (Fig. 14). Torque banjo fitting
bolt to 37 N·m (27 ft. lbs.).
NOTE: The lower turbocharger heat shield tabs
must over lap the upper heat shield tabs to prevent
fatiguing and early failure.
(20) Install turbocharger lower heat shield. Torque
upper and lower heat shield fasteners to 28 N·m (250
in. lbs.) (Fig. 11).
(21) Connect vacuum hoses to turbocharger.
(22) Connect upstream oxygen sensor.
(23) Install ignition coil. Connect electrical connec-
tor.
(24) Install electrical connector into bracket (Fig.
7).
(25) Install clean air hose (Fig. 10).
(26) Fill cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
(27) Change oil and filter.
(28) Install battery (Refer to 8 - ELECTRICAL/
BATTERY SYSTEM/BATTERY - INSTALLATION).
(29) Start the engine and inspect for exhaust
leaks. Repair exhaust leaks as necessary.
(30) Check the exhaust system for contact with the
body panels. Make the necessary adjustments, if
needed.
Fig. 13 Exhaust Manifold Tightening Sequence
Fig. 14 Banjo Bolt and Washers
1 - BANJO BOLT
2 - WASHERS
PL/SRT-4
EXHAUST SYSTEM AND TURBOCHARGER
11 - 9
TURBOCHARGER (Continued)
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