Turbocharger Assembly

Turbocharger Mounting:

REMOVAL
1. Disconnect negative battery cable.
2. Drain coolant from radiator.
3. Remove intercooler to intake manifold duct attaching bolt at thermostat housing.
4. Remove intercooler to manifold duct.
5. Disconnect air cleaner to turbocharger duct at turbocharger.
6. Disconnect air cleaner inlet duct.
7. Remove air cleaner and duct assembly.
8. Disconnect turbocharger to intercooler duct at turbocharger.
9. Remove turbocharger heat covers.
10. Disconnect oxygen sensor electrical connector.
11. Remove oxygen sensor.
12. Disconnect turbocharger water supply line at turbocharger.
13. Disconnect turbocharger oil supply line at turbo.
14. Disconnect vacuum line at turbocharger compressor outlet.
15. Disconnect vacuum line at actuator assembly.
16. Remove actuator arm to wastegate retaining clip.
17. Disconnect actuator arm from wastegate.
18. Remove wastegate actuator from turbocharger.
19. Remove cruise control servo and set aside.
20. Disconnect turbocharger down pipe at turbocharger.
21. Remove turbocharger water supply clamp and rubber hose.
22. Disconnect turbocharger oil drain hose at drain pipe.
23. Remove turbocharger to exhaust crossover attaching bolts.
24. Remove turbocharger from engine compartment.
25. If turbocharger is to be replaced, transfer oil and water lines to the new turbocharger unit.
26. Inspect for foreign material and determine the source.



INSTALLATION

1. Install turbocharger to engine compartment.
2. Install turbocharger to exhaust crossover attaching bolts and tighten to 23 Nm (17 lb-ft).
3. Connect turbocharger oil drain hose.
4. Connect turbocharger water supply line.
5. Connect turbocharger exhaust pipe attaching bolts and tighten to 23 Nm (17 lb-ft).
6. Install cruise control servo.
7. Install wastegate actuator.
8. Connect actuator arm to wastegate.
9. Install actuator arm to wastegate retaining clip.
10. Connect vacuum line at wastegate actuator.
11. Connect vacuum line at turbocharger compressor outlet.
12. Connect turbocharger oil supply line.
13. Connect turbocharger water return line.
14. Install oxygen sensor and tighten to 42 Nm (31 lb-ft).
15. Connect oxygen sensor electrical connector.
16. Install turbocharger heat covers.
17. Connect turbocharger to intercooler duct.
18. Install air cleaner assembly.
19. Connect air cleaner outlet duct.
20. Connect air cleaner to turbocharger duct.
21. Connect intercooler to intake manifold duct.
22. Install intercooler to intake manifold duct attaching bolts and tighten to 23 Nm (17 lb-ft).
23. Fill radiator with coolant.
24. Connect negative battery cable.

CAUTION: Prime turbocharger with oil before running the engine.

25. Crank with the fuel pump fuse removed until normal operating oil pressure is achieved.
26. To establish correct idle speed, see Idle Learn Procedures.
27. Inspect for intake, oil, coolant, and exhaust leaks.