Turbocharger Replacement
Turbocharger Replacement
Removal Procedure
Caution:
If a turbocharger has failed, clean any turbocharger debris or excessive oil from the charge air cooler system before installing the new turbocharger. Failure to clean debris from the charge air cooler system will cause severe turbocharger and engine damage upon startup. Failure to clean excessive oil from the charge air cooler system may cause an engine runaway condition on startup, resulting in severe engine damage.
1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (GE 47716) Cooling System Draining and Filling (GE 47716).
2. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement Intake Manifold Cover Replacement.
3. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement Service and Repair.
4. Remove the catalytic converter. Refer to Catalytic Converter Replacement.
Caution:
Do not twist the turbocharger oil feed pipe. Twisting of the feed pipe will result in the collapse and deformation of the plastic pipe, restricting oil flow and causing turbocharger damage. During turbocharger replacement, gently push the oil feed pipe towards the front of the engine to clear the turbocharger. Assistance may be required to keep the pipes clear of the turbocharger during removal or installation.
5. Remove the turbocharger oil feed pipe bolts.
6. Remove the turbocharger oil feed pipe gaskets.
7. Remove the turbocharger oil feed pipe (1).
8. Remove the turbocharger coolant return pipe bolts.
9. Remove the turbocharger coolant return pipe gaskets.
10. Remove the turbocharger coolant return pipe (1).
11. Remove the turbocharger air cooler outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement Charge Air Cooler Outlet Pipe Replacement.
12. Remove the turbocharger coolant feed pipe bolts.
13. Remove the turbocharger coolant feed pipe gaskets.
14. Remove the turbocharger coolant feed pipe (1).
15. Remove the turbocharger brace nuts.
16. Remove the turbocharger brace (1).
Note:
The PCV hose should not be disconnected from the camshaft cover. The PCV hose and the camshaft cover cannot be serviced individually.
17. Remove the PCV hose fitting bolt at the turbocharger.
18. Remove the PCV hose fitting from the turbocharger.
19. Remove the turbocharger nuts (1).
20. Remove the turbocharger (2) and the oil return pipe.
21. Remove the turbocharger gasket (3).
22. Remove the turbocharger oil return pipe bolts (3).
23. Remove the turbocharger oil return pipe (2) from the turbocharger.
24. Remove and discard the turbocharger oil return pipe gasket (1).
25. Disconnect vacuum hose as needed.
26. Disconnect coolant hoses as needed.
27. Disconnect electrical connectors as needed.
Installation Procedure
1. Install a new turbocharger oil return pipe gasket (1).
2. Install the turbocharger oil return pipe (2) on the turbocharger.
Caution:
Refer to Fastener Caution Fastener Caution.
3. Install the turbocharger oil return pipe bolts (3) and tighten to 10 Nm (89 lb in).
4. Attach the positive crankcase ventilation (PCV) hose and fitting with O-ring from the camshaft cover to the turbocharger.
5. Install the PCV hose fitting bolt and tighten to 10 Nm (89 lb in).
6. Lubricate the O-ring on the turbocharger oil return pipe with clean engine oil.
7. Install a new turbocharger gasket (3).
8. Install the turbocharger (2) with the oil return pipe.
9. Install the turbocharger nuts (1).
1. Tighten the turbocharger nuts to 30 Nm (22 lb ft).
2. Tighten the turbocharger nuts a second time to 35 Nm (26 lb ft).
10. Install the turbocharger brace (1).
11. Install the turbocharger brace nuts and tighten to 50 Nm (37 lb ft).
12. Install the catalytic converter. Refer to Catalytic Converter Replacement.
13. Install the turbocharger coolant feed pipe (1).
14. Install the turbocharger coolant feed pipe gaskets.
15. Install the turbocharger coolant feed pipe bolts.
1. Tighten the turbocharger coolant feed pipe bolts to 35 Nm (26 lb ft).
2. Tighten the turbocharger coolant feed pipe mounting bolt to 10 Nm (89 lb in).
16. Connect the PCV and hose assembly.
17. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement Service and Repair.
Caution:
Do not twist the turbocharger oil feed pipe. Twisting of the feed pipe will result in the collapse and deformation of the plastic pipe, restricting oil flow and causing turbocharger damage. During turbocharger replacement, gently push the oil feed pipe towards the front of the engine to clear the turbocharger. Assistance may be required to keep the pipes clear of the turbocharger during removal or installation.
Note:
The engine block end of the oil feed pipe fitting has an anti-rotation feature. Ensure that the fitting is fully seated against the block when installing the bolt.
18. Install the turbocharger oil feed pipe (1) on the engine block side.
19. Install the turbocharger oil feed pipe gasket on the engine block side.
20. Install the bolt and tighten to 40 Nm (30 lb ft).
21. Install the turbocharger coolant return pipe (1).
22. Install the turbocharger coolant return pipe gaskets.
23. Install the turbocharger coolant return pipe bolts and tighten to 35 Nm (26 lb ft).
Caution:
Do not twist the turbocharger oil feed pipe. Twisting of the feed pipe will result in the collapse and deformation of the plastic pipe, restricting oil flow and causing turbocharger damage. During turbocharger replacement, gently push the oil feed pipe towards the front of the engine to clear the turbocharger. Assistance may be required to keep the pipes clear of the turbocharger during removal or installation.
24. Install the turbocharger oil feed pipe (1) onto the turbocharger.
25. Install the turbocharger oil feed pipe gasket for the turbocharger side.
26. Install the turbocharger oil feed pipe bolt and tighten to 40 Nm (30 lb ft).
27. Install the catalytic converter. Refer to Catalytic Converter Replacement.
28. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (GE 47716) Cooling System Draining and Filling (GE 47716).
29. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement Intake Manifold Cover Replacement.
30. Replace the oil filter and fill the engine oil system. Refer to Engine Oil and Oil Filter Replacement Service and Repair.