Turbocharger System: Turbocharger: Removal: Removal

Remove the radiator closure panel. Refer to PANEL, CLOSURE, RADIATOR, REMOVAL .

Fig 1: Engine Cover, Cowl & Oil Dipstick
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Remove the engine cover (3).

Fig 2: Turbocharger Bracket & Fasteners
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Remove the turbocharger support bracket bolts (1).
Remove and discard the bracket nut (3).
Remove the turbocharger bracket (2).

Fig 3: Upper Heat Shield Bolts & Nuts
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Remove the bolts (1), nuts (2) and the turbocharger upper heat shield. Discard the nuts (2).

Fig 4: Charge Air Cooler Supply Hose, Heat Shield, Nuts & Bolts
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Remove the bolt (4) and the Charge Air Cooler (CAC) supply hose (5) from the turbocharger outlet.
Remove the bolt (1), nuts (2) and the lower catalytic converter heat shield (3).

Fig 5: Downstream & Upstream Oxygen Sensors With Retainer
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Disengage the wire harness from the retainer (3) and disconnect the upstream oxygen sensor connector (1) and downstream oxygen sensor connector (2).

Fig 6: Exhaust Cross-Under Pipe & Bolt
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Remove the center support bolt (1) from the cross-under pipe (2).

Fig 7: O2 Sensor & Flange Nuts
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Remove the exhaust flange nuts (1).
Reposition the cross-under pipe and discard the flange gasket.

Fig 8: Catalytic Converter, Support Mount & Bolts
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Remove the bolts (3) from the catalytic converter support bracket (2).

Fig 9: Turbocharger, Catalytic Converter Clamp & Catalytic Converter Assembly
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Loosen the catalytic converter clamp (2) at the turbocharger (1) and remove the converter assembly (3) from vehicle.

Fig 10: Converter/Turbo Gasket Ring
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Remove and discard the converter to turbo seal ring (1).

Fig 11: Covers/Caps
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NOTE:
Install the (special tool #10368, Set, Universal Protective Cap) into the open ports of the turbocharger.

Fig 12: Turbocharger Bypass Solenoid Electrical Connector, Air Hose To Waste-Gate Solenoid Valve & Turbocharger Coolant Outlet
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Unlock and disconnect the turbocharger surge valve wire harness connector (1).
Disconnect the wastegate actuator hose (2) from the turbocharger.
Remove the bolt (3) at the turbocharger coolant return tube and disconnect the tube from the coolant return pipe.

Fig 13: Coolant Return Tube Fitting At Turbocharger
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Remove the coolant return tube banjo bolt (1) and remove the turbocharger coolant return tube. Discard the banjo bolt washers.

Fig 14: Turbocharger Coolant Feed Banjo Bolt
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Remove the coolant supply tube banjo bolt (1) and position the tube aside. Discard the banjo bolt washers.

Fig 15: Engine Oil Cooler Heat Shields & Screws
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Remove the screws (1a) and remove the engine oil cooler heat shields (1b).

Fig 16: Turbocharger Oil Supply Tube Fitting At Oil Filter Housing
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CAUTION:
The oil supply and return lines MUST be replaced whenever the lines are loosened or removed.
Remove the oil supply tube banjo bolt (1) and remove the oil supply tube from the oil filter housing.

Fig 17: Turbocharger Oil Supply Tube & Fitting
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Remove the oil supply tube banjo bolt (1) and remove the turbocharger oil supply tube. The oil supply and return tubes must be replaced. The banjo bolts and banjo bolt washers must be replaced.

Fig 18: Oil Return Tubes At Turbocharger & Crankcase Bolts & Fitting
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Remove the bolts (1) from the oil return tube at the turbocharger.
Remove the bolt (2) from the oil return tube at the crankcase.
Remove the banjo bolt (3) and remove the turbocharger oil return tube. The oil supply and return tubes must be replaced. The banjo bolts and banjo bolt washers must be replaced.

Fig 19: Exhaust Manifold Heat Shield & Nuts
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Remove the nuts (1) from the exhaust manifold heat shield (2).

Fig 20: Exhaust Manifold Heat Shield & Nut
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Remove the nut (1) and remove the exhaust manifold heat shield (2).

Fig 21: Exhaust Manifold Nuts
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NOTE:
The turbocharger has been removed for clarity in illustration.
Remove and discard the nine exhaust manifold nuts (1). Remove the nine washers and remove the exhaust manifold.

Fig 22: Turbocharger Heat Shield
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Remove the turbocharger gasket/heat shield (1).
Remove and discard the nine exhaust manifold studs.
NOTE:
The exhaust manifold nuts and studs must be replaced. The washers can be reused. The exhaust manifold gasket and the turbocharger to manifold gasket must be replaced.

Fig 23: Manifold/Turbocharger Nuts
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With the exhaust manifold removed, invert the manifold and turbocharger as an assembly. Remove and discard the four nuts (1).
NOTE:
The turbocharger mounting nuts must be replaced.
Lift the manifold up and off of the turbocharger. Remove and discard the gasket.

Fig 24: Surge Valve, Connector & Bolts
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If replacing the turbocharger, remove the bolts (1) and surge valve (3). It will be necessary to install the surge valve on the replacement turbocharger.