Turbocharger: Service and Repair

Turbocharger Replacement

Removal Procedure




1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill LE5, L61) (Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (Static Fill LNF) (Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE 47716 Fill) (Cooling System Draining and Filling (GE 47716 Fill))
2. Remove the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement (Charge Air Cooler Inlet Pipe Replacement)
3. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (Air Cleaner Outlet Duct Replacement)
4. Remove the charge air cooler pipe bolts at the turbocharger.
5. Remove the charge air cooler pipe from the turbocharger.
6. Remove the air conditioning (A/C) evaporator hose assembly. Refer to Air Conditioning Evaporator Hose Assembly Replacement (Air Conditioning Evaporator Hose Assembly Replacement)
7. Remove the A/C rear condenser tube. Refer to Condenser Tube Replacement (LNF) (Condenser Tube Replacement)
8. Remove the brake vacuum booster vacuum hose from the booster. Refer to Power Brake Booster Vacuum Check Valve and Hose Replacement (2.2L) (Power Brake Booster Vacuum Check Valve and Hose Replacement)Power Brake Booster Vacuum Check Valve and Hose Replacement (2.0L) (Power Brake Booster Vacuum Check Valve and Hose Replacement)
9. Unbolt the transmission shiftier bracket from the transmission and leave cables attached and position aside.




10. Remove the turbocharger heat shield bolts (1) and shield.
11. Remove the catalytic converter. Refer to Catalytic Converter Replacement (LNF) (Service and Repair)Catalytic Converter Replacement (LAP) (Service and Repair)
12. Remove the heated oxygen sensor. Refer to Heated Oxygen Sensor Replacement - Sensor 1 (Heated Oxygen Sensor Replacement - Sensor 1)




13. Remove the turbocharger exhaust pipe heat shield bolts (1).
14. Remove the turbocharger exhaust pipe heat shield (2).




15. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair)
16. Remove the turbocharger exhaust pipe nuts (1).
17. Remove the turbocharger exhaust pipe (2).




18. Remove the turbocharger bracket bolt (1).
19. Remove the turbocharger bracket bolt (2) and bracket (3).
20. Remove the turbocharger brace bolts (4).
21. Remove the turbocharger brace nut (5) and brace (6).
22. Lower the vehicle.




23. Disconnect the engine wiring harness electrical connector from the turbocharger wastegate solenoid valve.




24. Reposition the vacuum hose clamp (5) at the turbocharger.
25. Remove the vacuum hose from the turbocharger.




26. Remove the engine wiring harness clip (1) from the turbocharger coolant feed pipe.




27. Remove the turbocharger coolant feed pipe bolt (1) at the turbocharger.
28. Remove and discard the turbocharger coolant feed pipe gasket.
29. Remove the turbocharger coolant feed pipe bolt (3) from the cylinder head.
30. Reposition the turbocharger coolant feed pipe out of the way.




31. Remove the positive crankcase ventilation (PCV) pipe (1) from the turbocharger. Reposition the PCV pipe (with fitting) out of the way. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service)
32. Remove the thermostat outlet housing and pipe. Refer to Engine Coolant Thermostat Housing Replacement (LNF) (Service and Repair)




33. Remove the turbocharger oil feed pipe bolts and pipe (1)
34. Remove and discard the turbocharger oil feed pipe gaskets.




35. Remove the turbocharger coolant return pipe bolts and pipe (1).
36. Remove and discard the turbocharger coolant return pipe gaskets.




37. Remove the turbocharger nuts (2).
38. Remove the turbocharger from the exhaust manifold studs while also removing the turbocharger oil return hose from the engine block.
39. Remove and discard the turbocharger gasket (1) and oil return hose O-ring seal (3).




40. If replacing the turbocharger, perform the following steps otherwise proceed to the step 7 in the Installation Procedure.
41. Remove the turbocharger oil return hose bolts (2) and hose from the turbocharger.
42. Remove and discard the turbocharger oil return hose gasket (1).




43. Reposition the vacuum hose clamps (1, 2, and 3) at the turbocharger wastegate solenoid valve.
44. Remove the vacuum hoses from the turbocharger wastegate solenoid valve.
45. Clean and inspect turbocharger. Refer to Turbocharger Cleaning and Inspection (46. Turbocharger Cleaning and Inspection)
46. Gently push back the turbocharger wastegate solenoid valve retainer (4) and remove the turbocharger wastegate solenoid valve from the bracket.

Installation Procedure




1. If replacing the turbocharger, perform the following steps otherwise proceed to step 7.
2. Install the turbocharger wastegate solenoid valve to the bracket until the retainer (4) clips into place.
3. Install the vacuum hoses to the turbocharger wastegate solenoid valve.
4. Position the vacuum hose clamps (1, 2, and 3) at the turbocharger wastegate solenoid valve.




5. Position a NEW turbocharger oil return hose gasket (1) on the turbocharger oil return hose.

Caution: Refer to Fastener Caution (Fastener Caution)

6. Install the turbocharger oil return hose and bolts (2) and tighten to 10 Nm (89 lb in).




7. Install NEW gaskets onto the turbocharger coolant return pipe fittings.
8. Install the turbocharger coolant return pipe (1) and bolts and tighten to 35 Nm (26 lb ft).
9. Install the thermostat outlet housing and pipe. Refer to Engine Coolant Thermostat Housing Replacement (LNF) (Service and Repair)




10. Install a NEW turbocharger gasket (1) onto the exhaust manifold studs.
11. Lubricate and install a NEW turbocharger oil return hose O-ring seal (3).
12. Install the turbocharger oil return hose to the engine block while also installing the turbocharger to the exhaust manifold studs.
13. Install the turbocharger nuts (2) and tighten to 35 Nm (26 lb ft).




14. Install NEW gaskets onto the turbocharger oil feed pipe fittings.
15. Install the turbocharger oil feed pipe (1) and bolts and tighten the bolts to 32 Nm (24 lb ft).




16. Position the PCV pipe (with fitting) and install the PCV fitting to the turbocharger.




17. Position the turbocharger coolant feed pipe to the turbocharger.
18. Install NEW gaskets onto the turbocharger coolant feed pipe fitting.
19. Install the turbocharger coolant feed pipe bolt (1) at the turbocharger and tighten the bolt to 35 Nm (26 lb ft).
20. Install the turbocharger coolant feed pipe bolt (3) to the cylinder head and tighten the bolt to 10 Nm (89 lb in.




21. Install the engine wiring harness clip (1) to the turbocharger coolant feed pipe.




22. Install the vacuum hose to the turbocharger.
23. Position the vacuum hose clamp (5) at the turbocharger.




24. Connect the engine wiring harness electrical connector to the turbocharger wastegate solenoid valve.




25. Install the turbocharger brace (6) and brace nut (5) and tighten to 50 Nm (37 lb ft).
26. Install the turbocharger brace bolts (4) and tighten the nut to 50 Nm (37 lb ft).
27. Install the turbocharger bracket (3) and bracket bolt (2) and tighten the nut to 25 Nm (18 lb ft).
28. Install the turbocharger bracket bolt (1) and tighten to 25 Nm (18 lb ft).




29. Install the turbocharger exhaust pipe (2).
30. Install the turbocharger exhaust pipe nuts (1) and tighten to 50 Nm (37 lb ft).




31. Install the turbocharger exhaust pipe heat shield (2).
32. Install the turbocharger exhaust pipe heat shield bolts (1) and tighten the nut to 10 Nm (89 lb in).
33. Install the transmission shiftier bracket with the cables to the transmission.
34. Install the brake vacuum booster vacuum hose to the booster. Refer to Power Brake Booster Vacuum Check Valve and Hose Replacement (2.2L) (Power Brake Booster Vacuum Check Valve and Hose Replacement)Power Brake Booster Vacuum Check Valve and Hose Replacement (2.0L) (Power Brake Booster Vacuum Check Valve and Hose Replacement)
35. Install the A/C rear condenser tube. Refer to Condenser Tube Replacement (LNF) (Condenser Tube Replacement)
36. Install the A/C evaporator hose assembly. Refer to Air Conditioning Evaporator Hose Assembly Replacement (Air Conditioning Evaporator Hose Assembly Replacement)
37. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair)
38. Install the heated oxygen sensor. Refer to Heated Oxygen Sensor Replacement - Sensor 1 (Heated Oxygen Sensor Replacement - Sensor 1)
39. Install the catalytic converter. Refer to Catalytic Converter Replacement (LNF) (Service and Repair)Catalytic Converter Replacement (LAP) (Service and Repair)




40. Lower the vehicle.
41. Install the turbocharger heat shield and bolts (1) and tighten the bolts to 10 Nm (89 lb in).




42. Install the charge air cooler pipe and gasket to the turbocharger.
43. Install the charge air cooler pipe bolts at the turbocharger and tighten the bolts to 22 Nm (16 lb ft).
44. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (Air Cleaner Outlet Duct Replacement)
45. Install the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement (Charge Air Cooler Inlet Pipe Replacement)
46. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill LE5, L61) (Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (Static Fill LNF) (Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE 47716 Fill) (Cooling System Draining and Filling (GE 47716 Fill))