Turbocharger: Service and Repair

Turbocharger Replacement

Removal Procedure




1. Drain the cooling system.
2. Remove the charge air cooler inlet pipe.
3. Remove the charge air cooler pipe bolts (1) at the turbocharger.
4. Remove the charge air cooler pipe from the turbocharger.




5. Remove the turbocharger heat shield bolts (1) and shield.
6. Remove the catalytic converter.




7. Remove the catalytic converter bracket bolt, nut, and bracket.
8. Lower the vehicle.




9. Remove the turbocharger brace nut and brace.




10. Disconnect the engine wiring harness electrical connector from the turbocharger boost sensor.




11. Reposition the vacuum hose clamp (5) at the turbocharger.
12. Remove the vacuum hose from the turbocharger.




13. Remove the engine wiring harness clip (1) from the turbocharger coolant feed pipe.




14. Remove the turbocharger coolant feed pipe bolt (1) at the turbocharger.
15. Remove and discard the turbocharger coolant feed pipe gasket.
16. Remove the turbocharger coolant feed pipe bolt (3) from the cylinder head.
17. Reposition the turbocharger coolant feed pipe out of the way.




18. Remove the positive crankcase ventilation (PCV) fitting bolt from the turbocharger. Reposition the PCV pipe (with fitting) out of the way.




19. Remove the turbocharger coolant return pipe bolts and pipe.
20. Remove and discard the turbocharger coolant return pipe gaskets.





Notice: 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.

21. Remove the turbocharger oil feed pipe bolts and pipe.
22. Remove and discard the turbocharger oil feed pipe gaskets.




23. Remove the turbocharger nuts (2).
24. Remove the turbocharger from the exhaust manifold studs while also removing the turbocharger oil return hose from the engine block.
25. Remove and discard the turbocharger gasket (1) and oil return hose O-ring seal (3).




26. If replacing the turbocharger, perform the following steps otherwise proceed to the step 7 in the installation procedure.
27. Remove the turbocharger oil return hose bolts (2) and hose from the turbocharger.
28. Remove and discard the turbocharger oil return hose gasket (1).




29. Reposition the vacuum hose clamps (1, 2, and 3) at the boost sensor.
30. Remove the vacuum hoses from the boost sensor.
31. Gently push back the boost sensor retainer (4) and remove the boost sensor from the bracket.

Installation Procedure




1. If replacing the turbocharger, perform the following steps otherwise proceed to step 7.
2. Install the boost sensor to the bracket until the retainer (4) clips into place.
3. Install the vacuum hoses to the boost sensor.
4. Position the vacuum hose clamps (1, 2, and 3) at the boost sensor.




5. Position a NEW turbocharger oil return hose gasket (1) on the turbocharger oil return hose.

Notice: Refer to Fastener Notice.

6. Install the turbocharger oil return hose and bolts (2).

Tighten the bolts to 10 N.m (89 lb in).




7. Install a NEW turbocharger gasket (1) onto the exhaust manifold studs.
8. Lubricate and install a NEW turbocharger oil return hose O-ring seal (3).
9. Install the turbocharger oil return hose to the engine block while also installing the turbocharger to the exhaust manifold studs.
10. Install the turbocharger nuts (2).

Tighten the nuts to 35 N.m (26 lb ft).




11. Install NEW gaskets onto the turbocharger oil feed pipe fittings.
12. Install the turbocharger oil feed pipe and bolts.

Tighten the bolts to 32 N.m (24 lb ft).




13. Install NEW gaskets onto the turbocharger coolant return pipe fittings.
14. Install the turbocharger coolant return pipe and bolts.

Tighten the bolts to 35 N.m (26 lb ft).




15. Install a NEW O-ring seal to the PCV fitting.
16. Position the PCV pipe (with fitting) and install the PCV fitting bolt to the turbocharger.

Tighten the bolt to 10 N.m (89 lb in).




17. Position the turbocharger coolant feed pipe to the turbocharger.
18. Install NEW gaskets onto the turbocharger coolant feed pipe fitting.
19. Install the turbocharger coolant feed pipe bolt (1) at the turbocharger.

Tighten the bolt to 35 N.m (26 lb ft).

20. Install the turbocharger coolant feed pipe bolt (3) to the cylinder head.

Tighten the bolt to 10 N.m (89 lb in).




21. Install the engine wiring harness clip (1) to the turbocharger coolant feed pipe.




22. Install the vacuum hose to the turbocharger.
23. Position the vacuum hose clamp (5) at the turbocharger.




24. Connect the engine wiring harness electrical connector to the turbocharger boost sensor.




25. Install the turbocharger brace bolt and nut.

Tighten the nut to 58 N.m (43 lb ft).




26. Raise and suitably support the vehicle.
27. Position the catalytic converter bracket to the engine.
28. Install the catalytic converter bracket bolt, and nut until snug.
29. Install the catalytic converter.
30. Tighten the catalytic converter bracket bolt and nut.

Tighten the bolt/nut to 58 N.m (43 lb ft).




31. Lower the vehicle.
32. Install the turbocharger heat shield and bolts (1).

Tighten the bolts to 10 N.m (89 lb in).




33. Install the charge air cooler pipe and gasket (2) to the turbocharger.
34. Install the charge air cooler pipe bolts (1) at the turbocharger.

Tighten the bolts to 22 N.m (16 lb ft).

35. Install the charge air cooler inlet pipe.
36. Fill the cooling system.