Turbocharger

Turbocharger













Removal

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Vehicle Jacking and Lifting.

2. Remove the turbocharger intake tube. For additional information, refer to Turbocharger Intake Tube Service and Repair.

3. Loosen the turbocharger outlet clamp.





4. Remove the bolt and position the ground wire aside. Disconnect the electrical connector pushpin.





5. Remove the conduit and position the wiring aside.
- Disconnect the locking tab.

- Remove the 3 bolts.

- Disconnect the pushpin and remove the wiring harness from the conduit.





6. Remove the 3 bolts for the Charge Air Cooler (CAC) tube.





7. Remove the 2 nuts, CAC tube and bracket.





8. Remove the turbocharger outlet clamp.





9. Remove and discard the 2 nuts. Position the exhaust downpipe aside.





10. Remove the LH 2 nuts and 2 bolts for the exhaust tube-to-exhaust manifold flange.
- Discard the 2 nuts.





11. Remove the RH 2 nuts and 2 bolts for the exhaust tube-to-exhaust manifold flange.
- Discard the 2 nuts.





12. Remove the EGR cooler clamp.





13. Remove the turbocharger inlet clamp and turbocharger adapter pipe.





14. Disconnect the turbocharger variable vane hydraulic control valve electrical connector and remove the wiring harness from the retaining clip.





15. Remove the bolt for the turbocharger oil feed tube.





16. Remove the 2 bolts and the turbocharger oil feed tube.
- Remove and discard the gasket and O-ring seal.





17. Remove the RH turbocharger mounting bolt.





18. Remove the 2 LH turbocharger mounting bolts.





19. NOTICE: Use care not to damage the turbocharger outlet hose when removing the turbocharger.

Position the turbocharger to remove the turbocharger drain tube. Remove the turbocharger from the vehicle through the passenger compartment.

- Remove and discard the O-ring seals.





Installation

1. NOTE: Install new drain tube O-ring seals and apply clean engine oil.

NOTE: Position the turbocharger outlet flange into the outlet hose as the turbocharger is positioned on the engine.

Position the turbocharger in the vehicle. Install the turbocharger drain tube and turbocharger.





2. NOTE: Apply anti-seize lubricant to the bolt threads prior to installation.

Install the 2 LH turbocharger mounting bolts.

- Tighten to 31 Nm (23 lb-ft).





3. NOTE: Apply anti-seize lubricant to the bolt threads prior to installation.

Install the RH turbocharger mounting bolt.

- Tighten to 31 Nm (23 lb-ft).





4. Prelubricate the oil inlet hole of the turbocharger assembly with clean engine oil and spin the compressor wheel several times to coat the bearings with oil.

5. NOTE: Use a new gasket and O-ring seal when installing the oil feed tube.

Position back the turbocharger oil feed tube and install a new gasket and the 2 bolts.

- Tighten to 23 Nm (17 lb-ft).





6. Install the bolt for the turbocharger oil feed tube.
- Tighten to 10 Nm (89 lb-in).





7. Connect the turbocharger variable vane hydraulic control valve electrical connector and install the wiring harness into the retaining clip.





8. Position the turbocharger adapter pipe and install the turbocharger inlet clamp.
- Tighten to 12 Nm (106 lb-in).





9. Install the EGR cooler clamp.
- Tighten to 6 Nm (53 lb-in).





10. NOTE: Apply anti-seize lubricant to the bolt threads prior to installation.

Install the 2 RH bolts and 2 new nuts for the exhaust tube-to-exhaust manifold flange.

- Tighten to 27 Nm (20 lb-ft).





11. NOTE: Apply anti-seize lubricant to the bolt threads prior to installation.

Install the 2 LH bolts and 2 new nuts for the exhaust tube-to-exhaust manifold flange.

- Tighten to 27 Nm (20 lb-ft).





12. Position the exhaust downpipe. Install the turbocharger exhaust clamp.
- Tighten to 10 Nm (89 lb-in).





13. Install the 2 new retaining nuts at the exhaust clamp.
- Tighten to 47 Nm (35 lb-ft).





14. NOTE: If there is any oil residue, clean both connecting ports and the inside surface of the CAC tube to prevent the tube from blowing off.

Position the CAC tube and bracket and install the 2 retaining nuts.





15. Install the 3 bolts for the CAC tube and oil fill tube.





16. Install the conduit and 3 bolts.
- Install the wiring harness into the conduit and connect the pushpins.

- Install the 3 bolts.

- Connect the locking tab.





17. Connect the electrical connector pushpin. Position the ground wire and install the bolt.





18. Tighten the turbocharger outlet clamp.
- Tighten to 12 Nm (106 lb-in).





19. Install the turbocharger intake tube. For additional information, refer to Turbocharger Intake Tube Service and Repair.