I have a 04 PT Cruiser turbo and have replaced the cartiage

Now having. The rest was cut off.

EXHAUST SYSTEM & TURBOCHARGER -2004 Chrysler PT Cruiser GT
Page 1 of 2
INSTALLATION

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.
Position turbocharger/exhaust manifold assembly in place. Gradually tighten fasteners, starting at center and progressing outward in both directions to 28 N.M (250 in. Lbs.). Raise and lower
vehicle for fastener access as necessary. Repeat tightening procedure until all fasteners are at specified torque.
3.
Fig. 37: Identifying Exhaust Manifold Tightening Sequence Courtesy of DAIMLERCHRYSLER CORP.
Install turbocharger elbow. Torque fasteners to 28 N.M (250 in. Lbs.). See Fig. 35
Install turbocharger upper heat shield. Torque fasteners to 28 N.M (250 in. Lbs.). See Fig. 35
Install turbocharger coolant supply line. Install NEW washers. Torque banjo fitting bolt to 30 N.M (22 ft. Lbs.). Torque flared fitting to 31 N.M (23 ft. Lbs.). See Fig. 32.
4. 5. 6.
.
.
Fig. 38: Installing Banjo Bolt & Washers Courtesy of DAIMLERCHRYSLER CORP.
7.
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. See Fig. 32.
Install turbocharger support bracket. Torque M8 fasteners to 28 N.M (250 in. Lbs.) And M10 fasteners to 54 N.M (40 ft. Lbs.). See Fig. 35.
Install turbocharger elbow support bracket. See Fig. 35
Install turbocharger to charge air cooler hose assembly. See Fig. 34 Install catalytic converter and intermediate pipe as an assembly.
12. Install fasteners securing catalytic converter to exhaust manifold. See Fig. 33. Torque fasteners to 28 N.M (250 in. Lbs.).
Install muffler. Connect muffler ground strap. See MUFFLER
8.
.
9. 10.
11.
.
13.
.

2/6/2012
EXHAUST SYSTEM & TURBOCHARGER -2004 Chrysler PT Cruiser GT
Page 2 of 2
14. 15. 16. 17.
Connect downstream oxygen sensor. Lower vehicle.
Connect vacuum hoses to turbocharger.
Install coolant return line. Install NEW washers. See Fig. 38. Torque banjo fitting bolt to 30 N.M (22 ft. Lbs.). See Fig. 32.
Connect oil supply line at turbocharger. Torque flared fitting to 31 N.M (23 ft. Lbs.). See Fig. 32
.
18.
NOTE:
The lower heat shield tabs must over lap the upper heat shield to
prevent fatiguing and premature failure of the union.
Install turbocharger lower heat shield. Torque fasteners to 28 N.M (250 in. Lbs.). See Fig. 35
20. Install upper intake manifold. See 2.4L 4-CYLINDER DOHC article. 21. Install upper intake manifold support bracket. See Fig. 31.
22. 23.
24.
19.
.
Connect vacuum hoses at throttle body and upper intake manifold. Connect air inlet hose at throttle body. See Fig. 30.
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
Connect throttle and speed control cables at throttle body.
Connect clean air hose to turbocharger. See Fig.
27. Install air cleaner housing and lid. See 2.4L 4-CYLINDER DOHC article.
Fill cooling system. See COOLING SYSTEM MECHANICAL Change oil and filter.
Connect negative battery cable.
31. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
32.
25. 26.
29.
Article.
28. 29.
30.
Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.

2/6/2012

Let me know what, if any, images you need.