Turbo Charger

REMOVAL 

1. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
2. Disconnect and isolate the negative battery cable.
3. Drain the turbocharger coolant system. Refer to DRAINING AND FILLING THE TURBOCHARGER COOLING SYSTEM .
4. Remove the turbocharger heat shield. Refer to TURBOCHARGER, REMOVAL AND INSTALLATION .
5. Remove the low pressure EGR valve. Refer to VALVE, EXHAUST GAS RECIRCULATION (EGR), REMOVAL AND INSTALLATION .

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6. Remove and discard the rear nuts (1) securing the turbocharger.

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   NOTE:

   Do not lift the turbocharger by the wastegate lever (1c).

7. Remove and discard the remaining nut (1a) and remove the turbocharger (1b).
NOTE:

The exhaust manifold heat shield and exhaust manifold gasket are part of the same assembly. They cannot be reused and must be replaced.

8. Remove the exhaust manifold heat shield. Refer to MANIFOLD, EXHAUST, REMOVAL AND INSTALLATION .

INSTALLATION 

1. Install a NEW  exhaust manifold heat shield. Refer to MANIFOLD, EXHAUST, REMOVAL AND INSTALLATION .

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   NOTE:

   Do not lift the turbocharger by the wastegate lever (1c).

2. Install the turbocharger (1b) with a NEW  upper front nut (1a) finger tight.

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3. Install the two NEW  rear nuts (1) finger tight.
   Fig 1: Turbocharger Tightening Sequence

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4. Tighten the three nuts in the sequence shown in two steps. Tighten according to the following torque values:
   • Step 1: All to 12 N.m (9 ft. lbs.)
   • Step 2: All to 25 N.m (18 ft. lbs.)

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5. Install the turbocharger heat shield (1c) with two bolts (1a) and nut (1b) tightened to the proper specification Refer to TORQUE SPECIFICATIONS  .

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6. Install a NEW  lower front nut (1) to the turbocharger heat shield and tightened to the proper specification Refer to TORQUE SPECIFICATIONS  .
7. Retighten the lower rear turbocharger nut (2) to 25 N.m (18 ft. lbs.).
8. Install the low pressure EGR valve. Refer to VALVE, EXHAUST GAS RECIRCULATION (EGR), REMOVAL AND INSTALLATION .
9. Install the turbocharger oil return pipe. Refer to LINES, TUBES AND HOSES, TURBOCHARGER, OIL AND COOLANT, REMOVAL AND INSTALLATION .
10. Install the turbocharger coolant supply pipe. Refer to LINES, TUBES AND HOSES, TURBOCHARGER, OIL AND COOLANT, REMOVAL AND INSTALLATION .
11. Install the water pump inlet tube. Refer to TUBE, WATER INLET, REMOVAL AND INSTALLATION .
12. Install the catalytic converter mounting bracket and the catalytic converter. Refer to CONVERTER, CATALYTIC, REMOVAL AND INSTALLATION .
13. Fill the turbocharger coolant system. Refer to DRAINING AND FILLING THE TURBOCHARGER COOLING SYSTEM .
14. Connect the negative battery cable.
15. Remove the support and lower the vehicle.