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2.4l Turbo Discussion of the 2.4l turbo

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Old 07-12-2009, 05:50 PM   #1
turbo water tube leak  
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primox is keeping the peace
hello all.
on my 2003 pt gt i found one morning a huge coolant leak on the ground. the bolt that holds the water line at the turbo broke inside. is it difficult to remove the turbo/manifold for repairs? i'm handy with tools.
any step by steps?
thx
r.
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Old 07-12-2009, 10:54 PM   #2
Re: turbo water tube leak  
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REMOVAL - LINES AND HOSES
NOTE: For line and hose location refer to (Turbocharger Lines and Hoses).

COOLANT SUPPLY LINE
Raise vehicle on hoist.
Drain cooling system (Refer to 7 - COOLING/ENGINE - STANDARD PROCEDURE).
Remove banjo bolt from coolant supply line at turbocharger (Coolant Lines - Banjo Fittings).
Disconnect coolant supply line flared fitting from brass fitting at engine block (Coolant Supply Line - Engine Block Fitting).
Remove coolant supply line.
COOLANT RETURN LINE
Drain cooling system (Refer to 7 - COOLING/ENGINE - STANDARD PROCEDURE).
Remove air cleaner housing (Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL).
Disconnect Inlet Air Temperature (IAT) sensor connector .
Disconnect Throttle Inlet Pressure (TIP) hose from charge air cooler hose .
Loosen hose clamp at throttle body.
Disconnect charge air cooler hose from throttle body. Reposition charge air cooler hose.
Remove fastener securing coolant return line bracket to cylinder head cover stud (Coolant Return Line Bracket).
Remove hose clamp from coolant return line at heater tube (Coolant Return Line Bracket). Disconnect hose from heater tube.
Remove banjo bolt from coolant return line at turbocharger (Coolant Lines - Banjo Fittings).
Remove coolant return line.
OIL SUPPLY LINE
Raise vehicle on hoist.
Remove elbow support bracket (Turbocharger Brackets and Heat Shields).
Disconnect oil supply line flared fitting from brass fitting at engine block (Oil Supply Line - Engine Block Fitting).
Lower vehicle.
Disconnect oil supply line flared fitting from brass fitting at turbocharger (Oil Supply Line - Turbocharger Fitting).
Remove oil supply line.
OIL RETURN LINE
Raise vehicle on hoist.
Remove the two fasteners securing the oil return line to the turbocharger.
Remove hose clamp from oil return line.
Remove oil return line from crankcase nipple (Turbocharger

REMOVAL - 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.

Disconnect negative battery cable.
Drain cooling system (Refer to 7 - COOLING/ENGINE - STANDARD PROCEDURE - DRAINING COOLING SYSTEM).
Remove air cleaner housing and lid (Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL).
Disconnect clean air hose from turbocharger (Clean Air Hose - 2.4L Turbo).
Disconnect throttle and speed control cables at throttle body.
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
Disconnect air inlet hose at throttle body (Charge Air Cooler Hoses).
Disconnect vacuum hoses at throttle body and upper intake manifold.
Remove upper intake manifold support bracket (Support Bracket).
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.

Remove turbocharger lower heat shield (Turbocharger Brackets and Heat Shields).
Disconnect oil supply line at turbocharger (Turbocharger Lines and Hoses).
Remove coolant return line (Turbocharger Lines and Hoses).
Disconnect vacuum hoses from turbocharger.
Raise vehicle on hoist.
Disconnect muffler ground strap. Remove muffler (Refer to 11 - EXHAUST SYSTEM/MUFFLER - REMOVAL).
Disconnect downstream oxygen sensor.
Remove fasteners securing catalytic converter to exhaust manifold (Converter to Exhaust Manifold Connection - 2.4L Turbo).
Remove catalytic converter and intermediate pipe as an assembly.
Remove turbocharger to charge air cooler hose assembly (Charge Air Cooler Hose).
Remove turbocharger elbow support bracket(Turbocharger Brackets and Heat Shields).
Remove turbocharger support bracket (Turbocharger Brackets and Heat Shields).
Remove oil return tube (Turbocharger Lines and Hoses).
Remove turbocharger coolant supply line (Turbocharger Lines and Hoses).
Remove turbocharger upper heat shield (Turbocharger Brackets and Heat Shields).
Remove turbocharger elbow (Turbocharger Brackets and Heat Shields).
Remove lower exhaust manifold fasteners that are accessible while vehicle is on hoist.
Lower vehicle.
Remove upper exhaust manifold fasteners.
Remove turbocharger/exhaust manifold assembly from above/between the engine and cowl panel.
Remove and discard exhaust manifold gasket.
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Old 07-13-2009, 12:55 AM   #3
Re: turbo water tube leak  
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thank you. im ok with all except
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.
is there any way around that or can i remove only the inlet side?
it looks like the broken piece is part of the inlet side.
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Old 07-13-2009, 05:14 AM   #4
Re: turbo water tube leak  
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Never had one apart so I do not know.
Have to wait for a 2.4L Turbo owner to answer that.
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Old 07-23-2009, 11:15 PM   #5
Re: turbo water tube leak  
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you can remove the turbo fromt he manifold it has a big clamp that you disconnect
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Old 02-25-2013, 11:20 AM   #6
Re: turbo water tube leak  
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i just did a complete swap on my 04 pt cruiser i used oem spec compressor side of the turbo without taking off the whole turbofold. the only tyhings i disconnected were the oil, supply and drain, water supply and drain, the hard pipe on the hot side, intake system, and catalytic converter( to gut it) no need to hoist anything, turbo is one vband like clamp( torque it down at 42lbs when reinstalling).



i Do have one hiccup.. hopefully someone has answers... i made a new coolant supply line as the other one was melted and had pin holes but now after the install of the new turbo, while the car idles it leaks from the coolant supply line at the hose pours coolant out under laod and while at idle.... WHY!!!!! help please this is my wifes daily driver. Is it because i didnt bleed the system first
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