Turbocharger Replacement

Turbocharger Replacement

Removal Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.

2. Drain the cooling system. Refer to Cooling System Draining and Filling (2.4L LEA) Cooling System Draining and FillingCooling System Draining and Filling (2.0L LHU) Cooling System Draining and Filling.

3. Remove the engine sight shield. Refer to Engine Sight Shield Replacement Engine Sight Shield Replacement.

4. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement.

5. Remove the air cleaner outlet rear duct. Refer to Air Cleaner Outlet Rear Duct Replacement Air Cleaner Outlet Rear Duct Replacement.

6. Remove the charge air cooler inlet hose - turbocharger side. Refer to Charge Air Cooler Inlet Hose Replacement (Turbocharger) Charge Air Cooler Inlet Hose Replacement (Turbocharger)Charge Air Cooler Inlet Hose Replacement (Charge Air Cooler) Charge Air Cooler Inlet Hose Replacement (Charge Air Cooler).

7. Remove the turbocharger heat shield. Refer to Turbocharger Heat Shield Replacement Turbocharger Heat Shield Replacement.

8. Remove the three way catalytic converter. Refer to Three-Way Catalytic Converter Replacement (2.4L LEA) Three-Way Catalytic Converter ReplacementThree-Way Catalytic Converter Replacement (2.0L LHU) Three-Way Catalytic Converter Replacement.

9. Remove the catalytic converter. Refer to Catalytic Converter Replacement (2.4L LEA) Catalytic Converter ReplacementCatalytic Converter Replacement (2.0L LHU) Catalytic Converter Replacement.

10. Remove the turbocharger oil return pipe. Refer to Turbocharger Oil Return Pipe Replacement Turbocharger Oil Return Pipe Replacement.

11. Remove the turbocharger oil feed pipe. Refer to Turbocharger Oil Feed Pipe Replacement Turbocharger Oil Feed Pipe Replacement.

12. Remove the turbocharger coolant feed pipe. Refer to Turbocharger Coolant Feed Pipe Replacement Turbocharger Coolant Feed Pipe Replacement.

13. Remove the turbocharger coolant return pipe. Refer to Turbocharger Coolant Return Pipe Replacement Turbocharger Coolant Return Pipe Replacement.




14. Disconnect the engine control module (ECM) wiring harness plug (3) from the turbocharger.

15. Loosen the vacuum hose clamp (1) and remove the vacuum hose (2) from the turbocharger air bypass valve.




16. Remove the positive crankcase ventilation hose bolt (3).

17. Remove the positive crankcase ventilation hose 2).

18. Remove and DISCARD the positive crankcase ventilation hose seal ring (1).

19. Remove the steering gear heat shield. Refer to Steering Gear Heat Shield Replacement Steering Gear Heat Shield Replacement.

20. Remove the heater inlet hose from the heater inlet. Refer to Heater Inlet Hose Replacement (2.4L LEA) Heater Inlet Hose ReplacementHeater Inlet Hose Replacement (2.0L LHU) Heater Inlet Hose Replacement.

21. Remove the heater outlet hose from the heater outlet. Refer to Heater Outlet Hose Replacement (2.4L LEA) Heater Outlet Hose ReplacementHeater Outlet Hose Replacement (2.0L LHU) Heater Outlet Hose Replacement.




22. Remove the brake and fuel pipe heat shield fasteners (2).

23. Remove the brake and fuel pipe heat shield (1).

24. Remove the turbocharger brace. Refer to Turbocharger Brace Replacement Turbocharger Brace Replacement.




25. Remove and DISCARD the 4 turbocharger nuts (2).

26. Remove the turbocharger (1).

27. Remove and DISCARD the turbocharger gasket (3).

Installation Procedure





Note:

* If the turbocharger is being replaced, the new turbocharger will not include mounting studs. New mounting studs and nuts must be used.

* If the turbocharger is being reused, only replace the nuts.

1. Replace the three way catalytic converter to turbocharger studs and nuts if necessary.

1. Install the turbocharger into a wise. Use softmetal braces.

2. Install the 4 NEW three way catalytic converter to turbocharger studs and tighten the studs to 25 Nm (18 lb ft).




2. Install a NEW turbocharger gasket (3).

3. Install the turbocharger (1).

Caution: Refer to Fastener Caution Fastener Caution.

4. Install the 4 NEW turbocharger nuts (2) and tighten to 30 Nm (22 lb ft).

5. Install the turbocharger brace. Refer to Turbocharger Brace Replacement Turbocharger Brace Replacement.




6. Install the brake and fuel pipe heat shield (1).

7. Install the brake and fuel pipe heat shield fasteners (2).

8. Install the heater inlet hose to the heater inlet. Refer to Heater Inlet Hose Replacement (2.4L LEA) Heater Inlet Hose ReplacementHeater Inlet Hose Replacement (2.0L LHU) Heater Inlet Hose Replacement.

9. Install the heater outlet hose to the heater outlet. Refer to Heater Outlet Hose Replacement (2.4L LEA) Heater Outlet Hose ReplacementHeater Outlet Hose Replacement (2.0L LHU) Heater Outlet Hose Replacement.

10. Install the steering gear heat shield. Refer to Steering Gear Heat Shield Replacement Steering Gear Heat Shield Replacement.




11. Install a NEW positive crankcase ventilation hose seal ring (1).

12. Install the positive crankcase ventilation hose (2).

13. Install the positive crankcase ventilation hose bolt (3) and tighten to 10 Nm (89 lb in).




14. Connect the ECM wiring harness plug (3) to the turbocharger.

15. Install the vacuum hose (2) to the turbocharger air bypass valve and tighten the clamp (1).

16. Install the turbocharger coolant return pipe. Refer to Turbocharger Coolant Return Pipe Replacement Turbocharger Coolant Return Pipe Replacement.

17. Install the turbocharger coolant feed pipe. Refer to Turbocharger Coolant Feed Pipe Replacement Turbocharger Coolant Feed Pipe Replacement.

18. Install the turbocharger oil feed pipe. Refer to Turbocharger Oil Feed Pipe Replacement Turbocharger Oil Feed Pipe Replacement.

19. Install the turbocharger oil return pipe. Refer to Turbocharger Oil Return Pipe Replacement Turbocharger Oil Return Pipe Replacement.

20. Install the three way catalytic converter. Refer to Three-Way Catalytic Converter Replacement (2.4L LEA) Three-Way Catalytic Converter ReplacementThree-Way Catalytic Converter Replacement (2.0L LHU) Three-Way Catalytic Converter Replacement.

21. Install the catalytic converter. Refer to Catalytic Converter Replacement (2.4L LEA) Catalytic Converter ReplacementCatalytic Converter Replacement (2.0L LHU) Catalytic Converter Replacement.

22. Lower and unsupport the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.

23. Install the turbocharger heat shield. Refer to Turbocharger Heat Shield Replacement Turbocharger Heat Shield Replacement.

24. Install the charge air cooler inlet hose - turbocharger side. Refer to Charge Air Cooler Inlet Hose Replacement (Turbocharger) Charge Air Cooler Inlet Hose Replacement (Turbocharger)Charge Air Cooler Inlet Hose Replacement (Charge Air Cooler) Charge Air Cooler Inlet Hose Replacement (Charge Air Cooler).

25. Install the air cleaner outlet rear duct. Refer to Air Cleaner Outlet Rear Duct Replacement Air Cleaner Outlet Rear Duct Replacement.

26. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement.

27. Install the engine sight shield. Refer to Engine Sight Shield Replacement Engine Sight Shield Replacement.

28. Fill the cooling system. Refer to Cooling System Draining and Filling (2.4L LEA) Cooling System Draining and FillingCooling System Draining and Filling (2.0L LHU) Cooling System Draining and Filling.