Turbocharger: Service and Repair

Turbocharger and Exhaust Manifold Removal and Installation

Exploded View










NOTE: Refer to the Exploded View if needed during this procedure.

Removal

1. Drain the engine coolant Testing and Inspection.

2. Remove the cowl cover and the under-cowl panel Service and Repair.

3. Remove the air cleaner Service and Repair.

4. Remove the charge air cooler.

5. Remove the warm up TWC Warm Up TWC Removal/Installation.

6. Remove the under-hood fuse/relay box from the bracket.






7. Remove the master cylinder reservoir (A), then remove the bracket (B).






8. Disconnect the heater hoses (A), then open the cable clamp, and remove the heater valve cable (B).





9. Remove the heater valve mounting bolt (C).

10. Remove the air bypass outlet pipe (A).






11. Disconnect the EVAP canister hose (A), then remove the intake air duct (turbocharger inlet pipe) (B).






12. Remove the intake air ducts (charge air cooler inlet hose/turbocharger outlet pipe assembly).






13. Disconnect the breather hose (A) and the water bypass hose (B), then remove the water bypass line mounting bolt (C).






14. Disconnect the turbocharger wastegate control solenoid valve connector and turbocharger boost control solenoid valve connector.

15. Disconnect the vacuum hose (A), then remove the vacuum line mounting bolt (B).





16. Remove the solenoid valve bracket mounting bolt (C), and loosen the solenoid valve bracket mounting bolt (D), then remove the solenoid valve bracket (E).

17. Remove the charge air cooler bracket (A).






18. Disconnect the water bypass hose (A) and the vacuum hoses (B).






19. Remove the water bypass pipe from the turbocharger.






20. Remove the intake air duct (turbocharger inlet connecting tube).






21. Raise the vehicle on the lift.

22. Remove the oil return pipe (A), then remove the oil feed filter bolt (B) at the oil feed pipe.






23. Remove the turbocharger bracket.






24. Lower the vehicle on the lift.

25. Remove the oil feed pipe (A).






26. Remove the turbocharger assembly, then seal the air inlet, the air outlet, the oil line hole, and the water line hole with tape.

NOTE: Use care when handling the turbocharger assembly. Do not turn the actuator rod adjusting nut, or touch the impeller.






27. Disconnect the water bypass hoses (A) from the exhaust manifold (B), then remove the exhaust manifold.





28. Remove the water bypass pipe (C), and disconnect the water bypass hose (D) from the exhaust manifold.

Installation

1. Install the water bypass pipe (A) with a new O-ring (B), then connect the water bypass hose (C).





2. Install the exhaust manifold (D) with a new gasket (E) new self-locking nuts (F) and bolts (G). Tighten the bolts and nuts in a crisscross pattern in three steps, beginning with the inner bolt.

3. Connect the water bypass hoses (H) to the exhaust manifold.

4. Pour new engine oil into the turbocharger oil line.

5. Install the turbocharger assembly (A) with a new gasket (B).

NOTE: Use care when installing the turbocharger assembly. Do not turn the actuator rod adjusting nut, or touch the impeller.






6. Check the oil feed pipe (A) for clogs. If it is clogged, clean or replace the pipe. Install the oil feed pipe with new washers (B), and loosely tighten the oil feed nut (C).






7. Raise the vehicle on the lift.

8. Install the turbocharger bracket.






9. Check the bolt (A) and the oil return pipe (B) for clogs. If they are clogged, clean or replace the bolt and/or pipe.





10. Loosely tighten the oil feed filter bolt with new washers (C), then install the oil return pipe with new gaskets (D).

11. Lower the vehicle on the lift.

12. Tighten the oil feed nut.






13. Raise the vehicle on the lift.

14. Tighten the oil feed filter bolt.






15. Lower the vehicle on the lift.

16. Install the intake air duct (turbocharger inlet connecting tube).






17. Install the water bypass pipe (A) with a new gasket (B).






18. Connect the water bypass hose (A) and the vacuum hoses (B).






19. Install the charge air cooler bracket.






20. Install the solenoid valve bracket (A) and connect the vacuum hose (B), then install the vacuum line mounting bolt (C).






21. Connect the turbocharger wastegate control solenoid valve connector and the turbocharger boost control solenoid valve connector.

22. Connect the breather hose (A) and the water bypass hose (B), then install the water bypass line mounting bolt (C).






23. Install the intake air ducts (charge air cooler inlet hose/turbocharger outlet pipe assembly) (A) with a new gasket (B).






24. Install the intake air duct (turbocharger inlet pipe) (A), then connect the EVAP canister hose (B).






25. Install the air bypass outlet pipe (A).






26. Install the heater valve mounting bolt (A).





27. Install the heater cable (B), and lock the clamp, then connect the heater hoses (C).

28. Install the bracket (A), then install the master cylinder reservoir (B).






29. Install the under-hood fuse/relay box to the bracket.






30. Install the warm up TWC Warm Up TWC Removal/Installation.

31. Install the charge air cooler.

32. Install the air cleaner Service and Repair.

33. Install the cowl cover and under-cowl panel A-Pillar Corner Trim Replacement.

34. Refill the radiator with engine coolant, and bleed the air from the cooling system with the heater valve open Service and Repair.