Removal
Turbocharger ReplacementRemoval Procedure
1. Disconnect both battery negative cables.
2. Move the hood to the service position by moving the hood hinge bolts (1) to the service positions (2).
3. Raise the vehicle. Refer to Vehicle Lifting.
4. Remove the exhaust pipe to the exhaust outlet clamp. Move the clamp onto the exhaust pipe.
5. If equipped with an automatic transmission, remove the transmission fluid fill tube to bell housing nuts.
6. Position the transmission fluid fill tube to the right side of the vehicle. The tube does not require removal from the transmission.
7. Remove the 3 nuts (2) and the left exhaust heat shield (3) at the front of the lower dash panel.
8. Remove the left exhaust pipe heat shield bolts.
9. Position the left exhaust pipe heat shield in order to access the left exhaust pipe to exhaust manifold bolts. Do not remove the heat shield from the vehicle at this time.
Important: Do not bend the exhaust pipe at the expansion area.
10. Remove the left exhaust pipe to exhaust manifold bolts (2).
11. Remove and discard the gasket.
Important: Do not bend the exhaust pipe at the expansion area.
12. Remove the right exhaust pipe to exhaust manifold bolts (1).
13. Remove and discard the gasket.
14. Remove the lower bolt (2) for the exhaust outlet shield.
15. Lower the vehicle.
16. Remove the upper intake manifold sight shield using the following procedure:
16.1. Remove the retaining bolt in the front of the shield.
16.2. Lift-up on the front of the shield.
16.3. Lift the shield off the rear bracket.
17. Drain the engine coolant.
Important: After removing the charged air cooler ducts, cover the turbocharger openings and the ducts with tape to prevent entry of objects.
18. Remove the air cleaner outlet duct from the air cleaner and the turbocharger.
19. Loosen both of the charged air cooler outlet duct to intake hose clamps.
Important: Do not use a screw driver or other tool to pry the hose loose. The hose can be torn or damage. Loosen the hose by twisting.
20. Remove the hose from the charged air cooler duct to the intake manifold tube.
21. Loosen the charged air cooler inlet duct to turbocharger cool air outlet clamp.
Important: Do not use a screw driver or other tool to pry the hose loose. The hose can be torn or damage. Loosen the hose by twisting.
22. Remove the charged air cooler inlet duct to turbocharger cool air outlet hose from the turbocharger.
23. Disconnect the A/C compressor clutch electrical connector.
24. Disconnect the A/C cut out switch electrical connector.
25. Remove the drive belt.
26. Remove the A/C compressor mounting bolts.
27. Move the A/C compressor with the hoses attached to the right side of the engine compartment.
28. Disconnect the turbocharger inlet coolant hose from the turbocharger coolant bypass valve.
29. Disconnect the turbocharger outlet coolant hose from the turbocharger.
30. Disconnect the PCV hose from the left valve rocker arm cover.
31. Position the hose out of the way.
32. Remove the wire connector from the intake heater.
33. If equipped, remove the intake air heater relay.
34. Remove the 3 bolts holding the heat shield to the turbocharger.
35. Remove the turbocharger heat shield.
36. Remove the remaining 2 bolts (1, 3) for the exhaust outlet heat shield.
37. Remove the exhaust outlet, heat shield.
38. Remove the 4 bolts and the 2 nuts for the exhaust outlet.
Important: The exhaust outlet does not require removal in order to remove the turbocharger.
39. Move the exhaust outlet to one side in order to access the right exhaust pipe to turbocharger bolts.
40. Remove and discard the exhaust outlet gasket.
41. Remove the right exhaust pipe to turbocharger bolts (2).
42. Remove the right exhaust pipe.
43. Remove and discard the gasket.
44. Move the exhaust outlet to one side in order to access the left exhaust pipe.
45. Remove the left exhaust pipe heat shield from the vehicle.
46. Remove the left exhaust pipe to turbocharger bolts (1).
47. Remove the left exhaust pipe.
48. Remove and discard the gasket.
49. Remove the turbocharger oil supply hose eye bolt, and washers.
50. Move the oil supply hose out of the way.
51. Remove the turbocharger oil drain pipe nuts at the flywheel housing.
52. Remove the turbocharger three mounting bolts.
53. Remove the turbocharger with the turbocharger oil drain pipe.
54. If replacing the turbocharger remove the following items:
^ Oil drain pipe
^ Coolant hose
55. Clean the following gasket surfaces:
^ Oil drain pipe to turbocharger
^ Oil drain pipe to flywheel housing
^ Air intake tube
^ Both exhaust pipe flanges
^ Both exhaust manifold flanges
^ Exhaust outlet
^ Turbocharger, exhaust outlet
^ Turbocharger, both exhaust pipe