Turbocharger: Service and Repair

Turbocharger Mounting Nuts & Wastegate Servo Location:

Air Cleaner And Throttle Body Assemblies:

REMOVAL

From Above The Engine Compartment

1. Disconnect negative battery cable, and drain cooling system.
2. Remove front engine mount through bolt and allow engine to rotate away from the firewall.
3. Separate the coolant line from the water box, (next to thermostat housing), and the turbocharger housing. Remove the line and fitting from the turbocharger.
4. Separate the oil feed line from the turbocharger housing.
5. Remove the wastegate actuator rod to wastegate retaining clip.
6. Remove the two upper and one lower (driver's side) turbocharger-to-exhaust manifold mounting nuts. (Leave the last nut on for now.)
7. Disconnect the oxygen sensor electrical connector, and disconnect the vacuum line to the wastegate servo motor.

From Below The Vehicle

1. Remove the passenger side, front wheel and tire assembly.
2. Remove right driveshaft assembly.
3. Remove turbocharger to engine block support bracket attaching bolts, then the bracket.
4. Disconnect and remove the oil drain back hose and fitting from the turbocharger housing.
5. Remove the one remaining turbocharger-to-exhaust manifold mounting nut.
6. Disconnect the articulated exhaust pipe joint from the turbocharger housing.
7. Remove the lower coolant line and turbocharger air inlet hose.
8. Remove the intercooler hose from the turbocharger.
9. Pull turbocharger off of the exhaust manifold mounting studs and lower the assembly down and out of the vehicle.

NOTE: The turbocharger must be removed from "below" the vehicle.

INSTALLATION

From Below The Vehicle

1. Clean the mating surfaces of the turbocharger and the exhaust manifold, and check the manifolds for cracks or distortion.
2. Install new gasket and position the turbocharger on the exhaust manifold mounting studs. Apply anti-seize compound to the mounting studs and install the lower passenger side mounting nut. Tighten the nut finger tight.
3. Apply thread sealant to the lower coolant line fitting and install into the turbocharger housing.
4. Install the lower coolant line to the fitting on the turbocharger.
5. Install oil drain back tube and fitting, with new gasket, to the turbocharger housing.
6. Install turbocharger to block support bracket and tighten the bolts finger tight. Torque the block bolt FIRST, to 40 ft-lbs (54 Nm). Torque the bolt to the turbocharger to 20 ft-lbs (27 Nm).
7. Insert the exhaust pipe into the articulated exhaust joint, and torque the 250 in-lbs (28 Nm).
8. Install the intercooler and air intake hoses to the turbocharger.
9. Install right driveshaft assembly.
10. Install the right wheel and tire assembly.

From Above The Engine Compartment

1. Install the three remaining turbocharger-to-exhaust manifold mounting nuts, and torque all four to 40 ft-lbs (54 Nm).
2. Connect the oxygen sensor electrical connector and connect the vacuum line to the wastegate servo motor.
3. Install the wastegate actuator rod retaining clip.
4. Install oil feed line to turbocharger bearing housing and torque to 125 in-lbs (14 Nm).
5. Apply thread sealant to the water box, (next to thermostat housing), and the turbocharger fittings. Install the coolant line and torque the fittings to 30 ft-lbs (41 Nm).
6. Align the front engine mount in the crossmember bracket and install the through bolt. Torque the through bolt to 40 ft-lbs (54 Nm).
7. Fill the coolant system and connect the negative battery cable.