Turbocharger Replacement

Turbocharger Replacement

Removal Procedure




1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill-LE5, L61) (Service and Repair)Cooling System Draining and Filling (Static Fill-LNF) (Service and Repair)Cooling System Draining and Filling (GE 47716 Fill) (Service and Repair).
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).
3. Remove the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement (Charge Air Cooler Inlet Pipe 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 turbocharger heat shield bolts (1) and shield.
7. Remove the heated oxygen (HO2) sensor. Refer to Heated Oxygen Sensor 1 Replacement (Service and Repair).




8. Remove the turbocharger exhaust pipe elbow heat shield bolts (1).
9. Remove the turbocharger exhaust pipe elbow heat shield (2).
10. Remove the catalytic converter. Refer to Catalytic Converter Replacement (LE5, L61) (Service and Repair)Catalytic Converter Replacement (LNF) (Service and Repair).




11. Remove the turbocharger exhaust elbow support bracket bolt (1).




12. Remove the turbocharger exhaust elbow to turbocharger retaining nuts (1).
13. Remove the turbocharger exhaust elbow (2).




14. Remove the turbocharger bracket upper retaining nut (1)




15. Loosen the turbocharger bracket lower retaining nut (1) and bolt (2).




16. Remove the stud (1) from the turbocharger.
17. Reposition the turbocharger bracket.
18. Lower the vehicle.




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




20. Reposition the vacuum hose clamp (1) at the turbocharger.
21. Remove the vacuum hose from the turbocharger.




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




23. Remove the turbocharger coolant feed pipe bolt (1) at the turbocharger.
24. Remove and discard the turbocharger coolant feed pipe gasket.
25. Remove the turbocharger coolant feed pipe bolt (3) from the cylinder head.
26. Reposition the turbocharger coolant feed pipe out of the way.




27. Remove the turbocharger coolant return pipe bolts and pipe.
28. Remove and discard the turbocharger coolant return pipe gaskets.




29. Remove the turbocharger oil feed pipe bolt (1) at the turbocharger and position aside.
30. Remove and discard the turbocharger oil feed pipe gaskets.




31. Disconnect the positive crankcase ventilation (PCV) pipe (1) from the turbocharger. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
32. Raise the vehicle.




33. Remove the turbocharger nuts (2).
34. Lower the vehicle.
35. Remove the turbocharger from the exhaust manifold studs while also removing the turbocharger oil return hose from the engine block.
36. Remove and discard the turbocharger gasket (1) and oil return hose O-ring seal (3).




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




40. Reposition the vacuum hose clamps (1, 2, and 3) at the turbocharger wastegate solenoid valve.
41. Remove the vacuum hoses from the turbocharger wastegate solenoid valve.
42. 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).

Tighten the bolts to 10 Nm (89 lb in).




7. Raise the vehicle.
8. Install a NEW turbocharger gasket (1) onto the exhaust manifold studs.
9. Lubricate and install a NEW turbocharger oil return hose O-ring seal (3).
10. Install the turbocharger oil return hose to the engine block while also installing the turbocharger to the exhaust manifold studs.
11. Install the turbocharger nuts (2).

Tighten the nuts to 35 Nm (26 lb ft).

12. Lower the vehicle.




13. Connect the positive crankcase ventilation (PCV) pipe (1) to the turbocharger. Refer to.




14. Install NEW gaskets onto the turbocharger oil feed pipe fittings.
15. Install the turbocharger oil feed pipe and bolt (1).

Tighten the bolts to 40 Nm (30 lb ft).




16. Install NEW gaskets onto the turbocharger coolant return pipe fittings.
17. Install the turbocharger coolant return pipe and bolts.

Tighten the bolts to 40 Nm (30 lb ft).




18. Position the turbocharger coolant feed pipe to the turbocharger.
19. Install NEW gaskets onto the turbocharger coolant feed pipe fitting.
20. Install the turbocharger coolant feed pipe bolt (1) at the turbocharger.

Tighten the bolt to 40 Nm (30 lb ft).

21. Install the turbocharger coolant feed pipe bolt (3) to the cylinder head.

Tighten the bolt to 10 Nm (89 lb in).




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




23. Install the vacuum hose to the turbocharger.
24. Position the vacuum hose clamp (1) at the turbocharger.




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




26. Install a NEW stud (1) to the turbocharger.




27. Tighten the turbocharger bracket lower retaining nut (1) and bolt (2).

Tighten the nut to 50 Nm (37 lb ft).

Tighten the bolt to 58 Nm (43 lb ft).




28. Install the turbocharger bracket upper retaining nut (1)

Tighten the nuts to 46 Nm (34 lb ft).




29. Install the turbocharger exhaust elbow (2).
30. Install the turbocharger exhaust elbow to turbocharger retaining nuts (1).

Tighten the nuts to 50 Nm (37 lb ft).




31. Install the turbocharger exhaust elbow support bracket bolt (1).

Tighten the bolts to 25 Nm (18 lb ft).




32. Install the turbocharger exhaust pipe elbow heat shield (2).
33. Install the turbocharger exhaust pipe elbow heat shield bolts (1).

Tighten the bolts to 10 Nm (89 lb in).




34. Lower the vehicle.
35. Install (HO2) sensor. Refer to Heated Oxygen Sensor 1 Replacement (Service and Repair).
36. Install the turbocharger heat shield and bolts (1).

Tighten the bolts to 10 Nm (89 lb in).




37. Install the charge air cooler pipe and gasket to the turbocharger.
38. Install the charge air cooler pipe bolts at the turbocharger.

Tighten the bolts to 22 Nm (16 lb ft).

39. Install the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement (Charge Air Cooler Inlet Pipe Replacement).
40. Install the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement (Charge Air Cooler Inlet Pipe Replacement).
41. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).
42. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill-LE5, L61) (Service and Repair)Cooling System Draining and Filling (Static Fill-LNF) (Service and Repair)Cooling System Draining and Filling (GE 47716 Fill) (Service and Repair).