Turbocharger - Removal

GAS ENGINES





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. Disconnect negative battery cable.
2. Drain cooling system Service and Repair.
3. Remove air cleaner housing and lid Air Cleaner Housing - Removal.
4. Disconnect clean air hose (1) from turbocharger (2).




5. Disconnect throttle and speed control cables at throttle body.
6. 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

7. Disconnect air inlet hose at throttle body (1).




8. Disconnect vacuum hoses at throttle body and upper intake manifold.
9. Remove upper intake manifold support bracket (2).




10. Remove upper intake manifold Intake Manifold - Removal.

CAUTION: Cover lower intake manifold opening with suitable cover to prevent any foreign objects from entering.

11. Disconnect oil supply line (1) at turbocharger.
12. Remove coolant return line (2).




13. Disconnect vacuum hoses from turbocharger.
14. Raise vehicle on hoist.
15. Disconnect muffler ground strap. Remove muffler Muffler - Removal.
16. Disconnect downstream oxygen sensor.
17. Remove fasteners (3 and 4) securing catalytic converter (5) to exhaust manifold.
18. Remove catalytic converter and intermediate pipe as an assembly.




19. Remove turbocharger to charge air cooler hose assembly (2).




20. Remove turbocharger lower heat shield (1).
21. Remove turbocharger elbow support bracket (4).
22. Remove turbocharger support bracket (2).
23. Remove turbocharger elbow (3).
24. Remove lower exhaust manifold fasteners that are accessible while vehicle is on hoist.
25. Lower vehicle.
26. Remove upper exhaust manifold fasteners.
27. Remove turbocharger/exhaust manifold assembly from above/between the engine and cowl panel.
28. Remove and discard exhaust manifold gasket.