Turbocharger: Service and Repair

Turbocharger

WARNING: Before beginning any service procedure, REFER to Safety Warnings . Failure to follow this instruction may result in serious personal injury.

Removal

NOTICE: 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.

NOTICE: The turbocharger wastegate actuator locknuts are not adjustable. Do not attempt to adjust the wastegate actuator locknuts or engine damage may occur.

NOTICE: Do not disassemble the turbocharger. Doing so may cause turbocharger or engine damage to occur.

1. With the vehicle in NEUTRAL, position it on a hoist. REFER to Lifting Points .

2. If equipped, remove the splash shield.

3. Remove the catalytic converter - 2.0L GTDI (Gasoline Turbocharged Direct Injection). REFER to Catalytic Converter - 2.0L GTDI .

4. Remove the lower CAC (Charge Air Cooler) inlet tube and the turbocharger inlet pipe. REFER to Intake Air System Components - Exploded View .

5. Drain cooling system. REFER to Cooling System Draining, Filling and Bleeding .

6. NOTE: Install new linked washers.
Remove the water outlet tube and water inlet hose assembly and discard the linked washers.
- Tighten to 28 Nm (21 lb-ft).





7. Disconnect the 2 turbocharger vacuum hose connections.





8. NOTE: Install a new cylinder block oil to engine turbocharger pipe and 2 seal washers.
Remove and discard the cylinder block oil to engine turbocharger pipe and the 2 seal washers.
- Tighten to 25 Nm (18 lb-ft).





9. Disconnect the 2 turbocharger electrical connectors.





10. Disconnect the 2 turbocharger vacuum hose connections.





11. Remove the 2 bolts and the heat shield.
- Tighten to 10 Nm (89 lb-in).





12. NOTICE: Install a new turbocharger oil drain tube and gaskets. By not doing so, the turbocharger oil drain tube may leak and cause engine damage.

NOTE: Install a new turbocharger oil drain tube and gaskets.
Remove and discard the turbocharger oil drain tube and gaskets.
- Tighten to 10 Nm (89 lb-in).





13. Remove the turbocharger and discard the 4 nuts and gasket.





Installation

1. NOTE: Install the turbocharger with a new gasket and 4 new nuts. Tighten the nuts in the sequence shown.
To install, reverse the removal procedure.
- Tighten to 50 Nm (37 lb-ft).