Removal And Installation: Turbocharger: Removal

NOTE: The turbocharger compressor vanes can be damaged by even the smallest particles. When removing any turbocharger or engine air intake system component, ensure that no debris enters the system. Failure to do so may result in damage to the turbocharger.

NOTE: Special attention needs to be given to the sealing ports for the oil supply, the oil return, and the coolant tubes, 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 tubes to ensure that there are no leaks or repeat repairs.

All vehicles

Drain the cooling system. Refer to: Specifications .
Remove the air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe .
Remove the CAC intake pipe. Refer to: Charge Air Cooler (CAC) Intake Pipe .
FWD (front wheel drive) vehicles
Remove the right front wheel and tire. Refer to: Wheel and Tire .
Remove the catalytic converter. Refer to: Catalytic Converter .
AWD (all-wheel drive) vehicles
Remove the power transfer unit. Refer to: Power Transfer Unit - Vehicles With: Power Transfer Unit Oil-to-Coolant Cooler . Refer to: Power Transfer Unit - Vehicles Without: Power Transfer Unit Oil-to-Coolant Cooler .
Remome the nuts and the catalytic converter support bracket.

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Loosen the clamp and position the catalytic conveter aside.

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All vehicles
Remove the bolts, then remove and discard the turbocharger oil return tube.

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Remove the bolt, then position the turbocharger oil supply tube out of the engine cylinder block.

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Remove the bolt, then position turbocharger coolant return tube out of the engine cylinder head.

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Remove the bolt, then position the turbocharger coolant supply tube out of the engine cylinder block.

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Detach the retainer and disconnect the turbocharger electrical connector.

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NOTE: The turbocharger gasket must be replaced as long as the turbocharger mounting nuts are loosened.

Remove the nuts and bolt, then remove the turbocharger heat shield and discard the bolt.

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Remove the turbocharger mounting nuts, then remove the turbocharger.

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Remove and discard the turbocharger gasket.

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If needed, remove and discard the turbocharger mounting studs.

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Remove the bolt and discard the turbocharger oil supply tube.

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If needed, remove the turbocharger coolant supply tube.

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- NOTE: This sub-step is only needed if the component was removed.
  
  NOTE: If the heat sleeve of coolant tubes is damaged/torn or needs to be replaced, the entire coolant tube assembly must be replaced.
  
  Remove and discard the turbocharger coolant tube O-ring seal.
- NOTE: Do not use a metal brush, damage to sealing area will result in leaks.
  
  NOTE: This sub-step is only needed if the component was removed.
  
  Use brake cleaner and a nylon brush to clean. Clean the turbocharger coolant tube sealing surfaces. Inspect the sealing surfaces for debris or damage, make sure the retaining bracket is not bent, check for squareness of the O-ring area. Install new components if needed. Refer to: Specifications .
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If needed, remove the turbocharger coolant return tube.

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- NOTE: This sub-step is only needed if the component was removed.
  
  NOTE: If the heat sleeve of coolant tubes is damaged/torn or needs to be replaced, the entire coolant tube assembly must be replaced.
  
  Remove and discard the turbocharger coolant tube O-ring seal.
- NOTE: Do not use a metal brush, damage to sealing area will result in leaks.
  
  Use brake cleaner and a nylon brush to clean. Clean the turbocharger coolant tube sealing surfaces. Inspect the sealing surfaces for debris or damage, make sure the retaining bracket is not bent, check for squareness of the O-ring area. Install new components if needed. Refer to: Specifications .

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