Removal Procedure
If a turbocharger has failed, clean any turbocharger debris or excessive oil from the charge air cooler system before installing the new turbocharger. Failure to clean debris from the charge air cooler system will cause severe turbocharger and engine damage upon startup.
- Battery Negative Cable Disconnection and Connection (without KL9)Battery Negative Cable Disconnection and Connection (with KL9) - Disconnect
- Turbocharger Heat Shield Replacement - Remove
- Air Cleaner Outlet Duct Replacement - Remove
- NOTE:
The fitting connection at the turbocharger is permanent. Do not remove the PCV tube and PCV valve assembly (2) from the camshaft cover unless replacement is necessary.
Remove the PCV valve tube assembly fastener (1) then only disconnect the tube at the turbocharger.
- Radiator Surge Tank Replacement (LUV, 2H0)Radiator Surge Tank Replacement (LE2) - Remove
- Charge Air Cooler Inlet Air Hose Replacement - Remove
- Turbocharger Oil Feed Pipe Replacement - Remove
- Turbocharger Coolant Return Pipe Replacement (LE2)Turbocharger Coolant Return Pipe Replacement (LUV) - Remove
- Turbocharger Coolant Feed Pipe Replacement (LUV)Turbocharger Coolant Feed Pipe Replacement (LE2) - Remove
- Catalytic Converter Replacement (2H0)Catalytic Converter Replacement (LUV)Catalytic Converter Replacement (LE2) - Remove
Electrical Connector(3)@Turbocharger Bypass Valve Solenoid(1) - Disconnect
- Disconnect the charge air bypass valve electrical connector (2).
- Raise the vehicle.
Remove the turbocharger oil return pipe bolts (1) carefully separate the pipe (2).
- Turbocharger Oil Return Pipe Gasket(3) Remove and DISCARD
- Lower the vehicle.
Turbocharger Nut(1) - Remove and DISCARD[4x]
- Turbocharger(2) - Remove
Remove and DISCARD the turbocharger heat shield with gasket (1).
- Clean the exhaust manifold sealing surface at the cylinder head.
- Clean the 4 turbocharger studs at the cylinder head.