Chrysler 300/300 Touring/300C, Dodge Magnum. Manual - part 1697

REMOVAL

WARNING: The normal operating temperature of
the exhaust system is very high. therefore, never
work around or attempt to service any part of the
exhaust system until it is cooled. special care
should be taken when working near the catalytic
converter. The temperature of the converter rises
to a high level after a short period of engine oper-
ation time.

1. Disconnect negative battery cable.

2. Disconnect differential pressure ports (2).

3. Remove exhaust from the diesel particulate filter

(1).

4. Remove the catalyst to diesel particulate filter fas-

teners.

5. Remove the diesel particulate filter assembly.

INSTALLATION

1. Install the diesel particulate filter assembly (1).

2. Install the catalyst to diesel particulate filter fasten-

ers.

3. Reconnect the exhaust to the diesel particulate fil-

ter (1).

4. Connect differential pressure ports (2).

5. Connect negative battery cable.

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EXHAUST SYSTEM

TURBOCHARGER SYSTEM

DESCRIPTION

CAUTION: The turbocharger is a performance part and must not be tampered with. The actuator bracket is
an integral part of the turbocharger. Tampering with the actuator or other components can reduce durability
by increasing cylinder pressure and thermal loading due to incorrect inlet and exhaust manifold pressure.
Poor fuel economy and failure to meet regulatory emissions laws may result. Increasing the turbocharger
boost WILL NOT increase engine power.

The turbocharger used on this vehicle is of the variable turbine type. These turbochargers use the entire exhaust
energy to boost efficiency of the turbocharger and the engine.

The advantages of a turbocharger with variable turbine geometry are:

•

Higher charge pressure already in the lower and in upper engine speed ranges.

•

Higher torque as a result of improved cylinder charge.

•

Reduction in exhaust emissions as a result of an improvement in the air supply of the engine.

•

Increased power output as a result of the higher charge pressure combined with a reduced exhaust back pres-
sure and thus improved charge cycle.

OPERATION

The exhaust gases of the engine are directed through
the exhaust manifold into the turbine housing (6) onto
the turbine wheel (7). The flow energy of the exhaust
gases cause the turbine wheel (7) to rotate. Conse-
quently, the compressor wheel, which is connected
through the turbine shaft with the turbine wheel (7), is
driven at the same speed. The fresh air (A) inducted
by the compressor wheel is compressed and passed
to the engine.

The charge pressure is controlled by varying the posi-
tion of the guide vanes (2). The guide stud (3) of the
control linkage of the boost pressure actuator turns
the adjusting ring (5) in the turbine housing (6). As a
result, all the guide vanes (3) whose guide studs (4)
likewise mesh into the adjusting ring (5), are also
turned.

At low speeds, the flow cross-section is reduced by
closing the guide vanes (2). Consequently the speed
at which the exhaust gas impacts on the turbine wheel
(7) is increased, as a result of which the speed of the turbocharger and thus the charge pressure rises.

At high engine speeds the guide vanes (2) are increasingly opened and the flow cross-section is thus enlarged, as
a result of which the speed of the turbocharger reduces and the charge pressure drops.

The turbocharger guide veins are controlled by the electronic actuator. The ECM monitors the boost and charge air
changes to the turbocharger system during operation. The ECM sends a PWM signal to the actuator. The actuator
will then respond to the signal adjusting the guide veins.

EXHAUST SYSTEM

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TURBOCHARGER

DIAGNOSIS AND TESTING - TURBOCHARGER

NOTE: Some horizontal and lateral movement of the turbine wheel is normal operation and should not be
confused with premature turbocharger bearing failure.

The turbocharger is not adjustable and has no replacable internal components. If a failure is determined, replace the
turbocharger.

CONDITION

POSSIBLE CAUSES

CORRECTION

CONDITION A

Possible Cause 1

Correction 1

Possible Cause 2

Correction 2

CONDITION B

Possible Cause 1

Correction 1

Possible Cause 2

Correction 2

REMOVAL - TURBOCHARGER

WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
NEVER WORK AROUND OR ATTEMPT TO SER-
VICE ANY PART OF THE EXHAUST SYSTEM UNTIL
IT IS COOL. CARE SHOULD BE TAKEN WHEN
WORKING

NEAR

THE

TURBOCHARGER.

THE

TEMPERATURE OF THE TURBOCHARGER RISES
TO A HIGH LEVEL AFTER A SHORT PERIOD OF
ENGINE OPERATION TIME.

NOTE: THERE IS NO PROCEDURE FOR REPAIR-
ING THE TURBOCHARGER. IF DAMAGE IS FOUND
DURING

INSPECTION,

THE

TURBOCHARGER

MUST BE REPLACED.

1. Disconnect negative battery cable.

2. Remove the engine trim cover.

3. Remove air intake tube (air cleaner to turbo) (1).

4. Remove engine cover front bracket (2).

5. Remove air tube (turbo to cooler) (3).

6. Remove the turbo heat shield (4).

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EXHAUST SYSTEM

7. Remove the exhaust clamp (elbow to converter)

(1).

8. Remove the turbo front bracket retaining bolts (1).

9. Drain cooling system (Refer to 7 - COOLING/EN-

GINE/COOLANT - STANDARD PROCEDURE).

10. Disconnect the downstream catalytic converter at

the extension pipe.

11. Disconnect the extension pipe to muffler.

12. Disconnect O2 sensor wire connector.

13. Reposition extension pipe and catalytic converter.

14. Lower vehicle and disconnect catalytic converter

to downstream catalytic converter clamp.

15. Remove upstream catalytic converter.

16. Disconnect transmission fill tube and trim cover

bracket and set aside.

17. Disconnect exhaust elbow at turbo (2).

18. Disconnect EGR tube at manifold to left cylinder

head (3).

19. Remove left and right exhaust manifold retaining

bolts and gaskets (4).

EXHAUST SYSTEM

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