Turbocharger - RH

Turbocharger - RH





RH Turbocharger (View 1 of 4)










RH Turbocharger (View 2 of 4)

NOTE: Heat insulating wrap remove for clarity.










RH Turbocharger (View 3 of 4)










RH Turbocharger (View 4 of 4)









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 blades are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist.

2. Drain the engine cooling system.

3. Remove the Air Cleaner (ACL) outlet pipe, RH ACL (Air Cleaner) pipe to-turbocharger pipe, RH turbocharger bypass hose and the RH turbocharger-to-Charge Air Cooler (CAC) pipe.

4. Remove the Air Conditioning (A/C) compressor belt.

5. Remove the 3 A/C (Air Conditioning) compressor bolts and position the A/C (Air Conditioning) compressor aside.





6. Remove the exhaust Y-pipe - dual catalytic converter.

Rear Wheel Drive (RWD) vehicles

NOTE: The exhaust Y-pipe - dual catalytic converter procedure requires the removal of the transmission insulator and retainer and the transmission crossmember. The transmission insulator and retainer and the transmission crossmember must be installed to continue the procedure.

7. Install the transmission insulator and retainer and the 3 transmission insulator and retainer bolts.
- Tighten to 90 Nm (66 lb-ft).






8. Install the transmission crossmember and the 4 transmission crossmember nuts and bolts (2 each side).
- Tighten to 90 Nm (66 lb-ft).






9. Lower the transmission onto the transmission crossmember and install the 2 transmission insulator and retainer nuts.
- Tighten to 103 Nm (75 lb-ft).






Four-Wheel Drive (4WD)

NOTE: The exhaust Y-pipe - dual catalytic converter procedure requires the removal of the transmission insulator and retainer and the transmission crossmember. The transmission insulator and retainer and the transmission crossmember must be installed to continue the procedure.

10. Loosely install the transmission insulator and retainer and the 4 transmission insulator and retainer bolts.





11. Position the transmission crossmember and loosely install the 2 transmission insulator and retainer nuts.





12. Install the 4 transmission crossmember bolts and nuts.
- Tighten the transmission insulator and retainer bolts to 90 Nm (66 lb-ft).

- Tighten the transmission crossmember bolts and nuts to 90 Nm (66 lb-ft).

- Tighten the transmission insulator and retainer nuts to 103 Nm (75 lb-ft).






All vehicles

13. Remove the starter.

14. NOTE: Use a 3/8 inch Jiffy-tite quick disconnect tool, such as a Snap-on(R) LDTSP4 or equivalent, to disconnect the turbocharger coolant supply tube.
NOTE: Position a drain pan prior to disconnecting the turbocharger coolant supply tube.
Using a commercially available quick disconnect tool, disconnect the turbocharger coolant supply tube at the turbocharger.
- Position the coolant supply tube aside.


15. NOTE: The heat insulating wrap is removed with the turbocharger bypass valve.
Disconnect the turbocharger bypass valve electrical connector. Disconnect the wastegate hose and the 2 bypass vacuum hoses.

- Remove the turbocharger bypass valve from the bracket and position aside.


16. Remove the 4 bolts for the turbocharger oil return tube assembly.
- Remove the 2 turbocharger center housing bolts.

- Remove the oil pressure tube bolt.

- Remove the oil drain tube bolt.

- Remove and discard the turbocharger oil return tube gasket.


17. Remove the turbocharger bracket bolt.

18. NOTE: Use a 3/8 inch Jiffy-tite quick disconnect tool, such as a Snap-on(R) LDTSP4 or equivalent, to disconnect the turbocharger coolant return tube.
Using a commercially available quick disconnect tool, disconnect the RH turbocharger coolant return tube at the turbocharger.


19. Remove the 3 turbocharger mounting bolts and the turbocharger.
- Discard the turbocharger exhaust manifold gasket.


20. Remove the turbocharger oil return tube assembly.
- Remove and discard the turbocharger oil return tube O-ring seal.


21. Loosen the 2 turbocharger bracket-to-cylinder block bolts.

22. NOTE: Use a 3/8 inch Jiffy-tite quick disconnect tool, such as a Snap-on(R) LDTSP4 or equivalent, to disconnect the turbocharger coolant tubes.
If necessary, remove the turbocharger coolant supply and the coolant outlet tubes.


23. If necessary, remove the 2 turbocharger exhaust flange stud bolts and the turbocharger exhaust flange.
- Discard the 2 turbocharger exhaust flange stud bolts and the turbocharger exhaust flange gasket.






Installation

All vehicles

1. NOTE: Apply high temperature nickel anti-seize lubricant to the turbocharger exhaust flange stud bolt threads prior to installation of the turbocharger exhaust flange.
If removed, using a new turbocharger exhaust flange gasket, install the turbocharger exhaust flange and the 2 new turbocharger exhaust flange stud bolts.

- Tighten to 40 Nm (30 lb-ft).






2. If removed, install the turbocharger coolant supply and the coolant outlet tubes.

3. NOTE: Lubricate the cylinder block bore with clean engine oil.
NOTE: Apply clean engine oil to the turbocharger oil return tube O-ring seal.
NOTE: Make sure the turbocharger oil supply tube is positioned in the cylinder block during the installation of the turbocharger oil return tube assembly.
Using a new turbocharger oil return tube O-ring seal, install the turbocharger oil return tube assembly.


4. Using a new turbocharger exhaust manifold gasket, install the RH turbocharger and the 3 turbocharger mounting bolts.
- Tighten finger tight.


5. Install the turbocharger bracket bolt.
- Tighten finger tight.


6. Tighten the 3 turbocharger mounting bolts.
- Tighten to 32 Nm (24 lb-ft).


7. Tighten the turbocharger bracket bolt.
- Tighten to 18 Nm (159 lb-in).


8. Tighten the 2 turbocharger bracket-to-cylinder block bolts.
- Tighten to 10 Nm (89 lb-in).


9. NOTE: The best access for the tube is from above.
Connect the RH turbocharger coolant return tube into the turbocharger.


10. Using a new turbocharger oil return tube gasket, install the 2 turbocharger center housing bolts at the turbocharger. Tighten in the following stages:
- Stage 1: Install the bolt for the oil pressure tube side halfway.

- Stage 2: Install the bolt for the oil drain tube side and tighten to 10 Nm (89 lb-in).

- Stage 3: Tighten the bolt for the oil drain tube side an additional 30 degrees.

- Stage 4: Tighten the bolt for the oil pressure tube side to 10 Nm (89 lb-in).

- Stage 5: Tighten the bolt for the oil pressure tube side an additional 30 degrees.


11. Install the turbocharger oil return tube bolt at the cylinder block. Tighten in the following stages:
- Stage 1: Tighten to 8 Nm (71 lb-in).

- Stage 2: Tighten an additional 30 degrees.


12. Install the turbocharger oil supply tube bracket and bolt. Tighten in the following stages:
- Stage 1: Tighten to 8 Nm (71 lb-in).

- Stage 2: Tighten an additional 30 degrees.


13. Position back the turbocharger bypass valve on the bracket. Connect the 2 bypass vacuum hoses and the wastegate hose.
- Connect the turbocharger bypass valve electrical connector.


14. Connect the turbocharger coolant supply tube to the turbocharger.

15. Install the starter.

4WD (Four-Wheel Drive) vehicles

16. Remove the 2 transmission insulator and retainer nuts.





17. NOTE: Right side shown, left side similar. Transmission crossmember removed for clarity.
Remove the 4 transmission insulator and retainer bolts.






18. Support the transfer case.





19. Remove the 4 transmission crossmember nuts and bolts.





20. Remove the transmission insulator and retainer.

RWD (Rear Wheel Drive)

21. Remove the 2 transmission insulator and retainer nuts.





22. Position a suitable high-lift transmission jack under the transmission.

23. Remove the 4 transmission crossmember nuts and bolts (2 each side) and remove the transmission crossmember.





24. Remove the 3 transmission insulator and retainer bolts and remove the transmission insulator and retainer.





All vehicles

25. Install the exhaust Y-pipe - dual catalytic converter.

26. Position the A/C (Air Conditioning) compressor and install the 3 A/C (Air Conditioning) compressor bolts.
- Tighten to 25 Nm (18 lb-ft).






27. Install the A/C (Air Conditioning) compressor belt.

28. Install the ACL (Air Cleaner) outlet pipe, RH ACL (Air Cleaner) pipe to-turbocharger pipe, RH turbocharger bypass hose and the RH turbocharger-to-CAC (Charge Air Cooler) pipe.

29. Fill the engine cooling system.