Turbocharger Replacement

Turbocharger Replacement

Removal Procedure

1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement (LCV) Intake Manifold Cover ReplacementIntake Manifold Cover Replacement (LTG) Intake Manifold Cover Replacement.

2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (LCV) Air Cleaner Outlet Duct ReplacementAir Cleaner Outlet Duct Replacement (LTG) Air Cleaner Outlet Duct Replacement.




3. Remove the turbocharger heat shield (2). Refer to Turbocharger Heat Shield Replacement Turbocharger Heat Shield Replacement.

4. Remove the catalytic converter. Refer to Catalytic Converter Replacement (LUK) Service and RepairCatalytic Converter Replacement (LCV) Service and RepairCatalytic Converter Replacement (LTG) Service and Repair.

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

6. Remove the PCV hose. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (LCV) Service and RepairPositive Crankcase Ventilation Hose/Pipe/Tube Replacement (Camshaft Cover to Air Cleaner Resonator to Outlet Duct) Service and Repair.




7. Remove the turbocharger oil return pipe bolts (1).




8. Remove the turbocharger oil feed pipe bolts (1).




9. Remove the turbocharger coolant feed pipe bolts (1).




10. Remove the turbocharger nuts (1) and turbocharger (2).

11. For turbocharger cleaning and inspection, refer to Turbocharger Cleaning and Inspection Turbocharger Cleaning and Inspection.

Installation Procedure

Note: The exhaust pipe studs do not come installed on new turbochargers. If the turbocharger is being replaced, new studs will need to be installed.




2. Install a NEW turbocharger gasket (3) on the turbocharger.

3. Install NEW turbocharger oil feed and oil return pipe gaskets (4, 5).

4. Install the turbocharger (1).

5. Install NEW turbocharger nuts (2) finger tighten.

Caution: Refer to Fastener Caution Fastener Caution.

6. Install the turbocharger oil feed and return pipe bolts (6) at the engine block. Tighten the bolts to 10 Nm (89 lb in).

7. Install the PCV hose. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (LCV) Service and RepairPositive Crankcase Ventilation Hose/Pipe/Tube Replacement (Camshaft Cover to Air Cleaner Resonator to Outlet Duct) Service and Repair.




8. Tighten the turbocharger nuts in sequence to 30 Nm (22 lb ft).




9. Install the turbocharger coolant feed pipe bolts (1) and tighten to 10 Nm (89 lb in).

10. Install the catalytic converter. Refer to Catalytic Converter Replacement (LUK) Service and RepairCatalytic Converter Replacement (LCV) Service and RepairCatalytic Converter Replacement (LTG) Service and Repair.




11. Install the turbocharger heat shield (2). Refer to Turbocharger Heat Shield Replacement Turbocharger Heat Shield Replacement.

12. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (LCV) Air Cleaner Outlet Duct ReplacementAir Cleaner Outlet Duct Replacement (LTG) Air Cleaner Outlet Duct Replacement.

13. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement (LCV) Intake Manifold Cover ReplacementIntake Manifold Cover Replacement (LTG) Intake Manifold Cover Replacement.