Removal And Installation: Turbocharger: Removal

WARNING: This page is about a different variant/trim than selected.

NOTE: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.

NOTE: Special attention needs to be given to the sealing ports for the oil feed, the oil drain, and the coolant lines, on turbocharged engines. The sealing ports must be totally clean and free from O-ring residue, have no damage to the sealing surface and the lines to ensure that there are no leaks or repeat repairs.

NOTE: Removal steps in this procedure may contain installation details.

Disconnect the battery. Refer to: Battery Disconnect and Connect .
1. Loosen the clamps.
  Torque
  
  : 44 lb.in (5 Nm)
2. Remove the bolt and the air cleaner outlet pipe.
  Torque
  
  : 44 lb.in (5 Nm)
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1. Disconnect the crankcase ventilation tube quick release coupling. Refer to: Quick Release Coupling .
2. Remove the TC air inlet pipe bolt.
  Torque
  
  : 44 lb.in (5 Nm)
3. Remove the TC air inlet pipe ball stud.
  Torque
  
  : 44 lb.in (5 Nm)
4. Loosen the TC air inlet pipe clamp and remove the TC inlet pipe.
  Torque
  
  : 44 lb.in (5 Nm)
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With the vehicle in NEUTRAL, position it on a hoist. Refer to: Jacking and Lifting - Overview .
1. If equipped. Remove the screws and the deflector shield.
2. Remove the screws and the under engine shield.
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1. Remove the TC outlet pipe mounting bracket bolts.
  Torque
  
  : 89 lb.in (10 Nm)
2. Loosen the TC outlet pipe clamps and remove the TC outlet pipe.
  Torque
  
  : 44 lb.in (5 Nm)
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NOTE: Make sure that the exhaust flexible pipe is not forcibly bent or twisted.

Support the exhaust flexible pipe with a support wrap or suitable splint. Use the General Equipment: Cable Ties

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Remove the catalytic converter bracket nuts.

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NOTE: Make sure that a new component is installed.

Remove the following items:
1. Loosen the clamp nut.
  Torque
  
  : 177 lb.in (20 Nm)
2. Position the clamp aside.
3. Remove and discard the TC exhaust flange gasket.
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NOTE: Make sure that the exhaust flexible pipe is not forcibly bent or twisted.

Install a cable tie.

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1. Remove the catalytic converter retaining plate.
2. Remove the catalytic converter bracket.
3. Remove the catalytic converter brace.
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Drain the cooling system. Refer to: COOLING SYSTEM DRAINING, VACUUM FILLING AND BLEEDING .
NOTE: Both water outlet tube clamps must be installed between the 2 paint stripes on hoses.
1. NOTE: Inspect the banjo bolt, the line surface for flatness and square-ness and the sealing surface for damage. ALWAYS USE NEW SEALING WASHERS. Use brake cleaner and a NYLON brush to clean. DO-NOT USE A METAL BRUSH; DAMAGE TO SEALING AREA WILL RESULT IN LEAKS.
  
  Release the TC coolant tube clamps, loosen the retaining bolts and then remove the TC cooling tube assembly.
  
  Torque
  
  : 21 lb.ft (28 Nm)
2. Remove and discard the TC coolant tube sealing washers.
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Remove the TC heat shield retaining bolts and the TC heat shield.
Torque

: 89 lb.in (10 Nm)

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1. Disconnect the TC wastegate regulating valve solenoid electrical connector.
2. Disconnect the TC control hose clamps and position the TC control hoses aside.
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NOTE: Inspect the banjo bolt, the line surface for flatness and square-ness and the sealing surface for damage. ALWAYS USE NEW SEALING WASHERS. Use brake cleaner and a NYLON brush to clean. DO-NOT USE A METAL BRUSH; DAMAGE TO SEALING AREA WILL RESULT IN LEAKS.

Remove the TC oil feed tube retaining bolts, discard the sealing washers and remove the TC oil feed tube.

Torque

: 18 lb.ft (25 Nm)

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NOTE: Make sure that a new turbocharger oil supply filter is installed.

Remove and discard the TC oil supply filter.

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NOTE: Make sure that a new turbocharger oil drain tube is installed. By not doing so, the turbocharger oil drain tube may leak and cause engine damage.

Remove the TC oil drain tube bolts and discard the TC oil drain tube.

Torque

: 89 lb.in (10 Nm)

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NOTE: Make sure that 2 new turbocharger oil drain tube gaskets are installed. By not doing so, the turbocharger oil drain tube may leak and cause engine damage.

Remove and discard the TC oil drain tube gaskets.

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Remove and discard the TC mounting nuts and remove the TC.

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1. If needed, remove the TC cooling tube retainer.
  Torque
  
  : 89 lb.in (10 Nm)
2. NOTE: Inspect the banjo bolt, the line surface for flatness and square-ness and the sealing surface for damage. ALWAYS USE NEW SEALING WASHERS. Use brake cleaner and a NYLON brush to clean. DO-NOT USE A METAL BRUSH; DAMAGE TO SEALING AREA WILL RESULT IN LEAKS.
  
  If needed, loosen the TC cooling tube retaining bolt and then remove the TC cooling tube.
  
  Torque
  
  : 21 lb.ft (28 Nm)
- If the TC cooling tube was removed, then remove and discard the TC coolant tube sealing washers.
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Remove and discard the TC mounting studs and the gasket.
Torque

: 150 lb.in (17 Nm)

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