Turbocharger - Removal

REMOVAL

Special Tools:






1. Disconnect and isolate the negative battery cable.
2. Remove the front fascia (1) Front Bumper Fascia - Removal.





3. Remove the right and left headlamp units (2) Headlamp Unit - Removal.





4. Disconnect the upper coolant hose from the radiator.
5. Disconnect the electrical connector from the cooling fan resistor (1) located on the cooling fan shroud.





6. Disconnect the cooling fan electrical connector (3).
7. Disconnect the lower coolant hose from the radiator.
8. Recover the refrigerant from the refrigerant system A/C Evaporator Cleaning.





9. Remove the bolt (4) and disconnect the A/C liquid line (1) and the A/C compressor discharge line (2) from the A/C condenser tapping block (3).
10. Separate the A/C liquid line from the A/C compressor discharge line. Remove and discard the dual plane seals.
11. Install plugs in, or tape over, the opened refrigerant line fittings and condenser ports.





12. Press down the latch release (3) and remove the hood latch cable (2) from the latch.





13. Disconnect the wire harness connector (2) from the right and left front impact sensors (1) Front. It is not necessary to unbolt the sensor from the frame.





14. Disconnect the wire harness connector (1) from the horn (2).
15. Disengage the wire harness from the bumper reinforcement.





16. Disengage the block heater wire harness retainer (1) from the upper core support.





17. Disconnect the throttle body inlet hose (1) and turbocharger outlet hose (2) at the lower quick disconnects located behind the cooling fan (3).





18. Remove the four upper bolts (1), eight center bolts and washers (2), eight lower bolts and washers (3) and the cooling module assembly (4) from the vehicle.





19. Remove the turbocharger bracket bolts (1).
20. Remove and discard the bracket nut (3).
21. Remove the turbocharger bracket (2).





22. Remove the turbocharger upper heat shield bolts (1) and nuts (2).





23. Remove the Charge Air Cooler (CAC) supply hose (5) from the turbocharger.
24. Remove the catalytic converter heat shield (3).

CAUTION: The oil supply and return lines MUST be replaced whenever the lines are loosened or removed.





25. Disconnect the vacuum line to the actuator pump (2).
26. Disconnect the turbocharger pressure sensor hose (1).
27. Remove the coolant return line located on the rear side of the turbocharger.
28. Remove the coolant supply banjo bolt (4) and position the line aside.
29. Remove the oil supply line banjo bolt (3).
30. Remove the lower oil return line (5).
31. Disconnect the turbocharger surge valve connector (6).
32. Raise and support vehicle.





33. Remove the front exhaust pipe support bolt (2).
34. Remove the exhaust flange nuts (1).





35. Remove the nuts that secure the cross under pipe to the catalytic converter.
36. Remove the front exhaust pipe and flange gasket.
37. Remove the lower catalytic converter support mount (2).
38. Lower the vehicle.





39. Disconnect the O2 sensor connector.
40. Loosen the catalytic converter clamp (2) at the turbocharger (1) and remove the converter assembly from vehicle.





41. Remove the converter to turbo seal ring (1).






NOTE: Install the (10368) into the open bores on the turbo to avoid any foreign material to enter the turbocharger.

42. Remove the two bolts and the nut that secure the shield to the exhaust manifold.
43. Remove the shield.






NOTE: The turbocharger has been removed for clarity.

44. Remove and discard the nine exhaust manifold nuts (1).
45. Remove the nine washers.

NOTE: The exhaust manifold nuts must be replaced. The washers can be reused.






46. With the manifold removed, invert the manifold and turbocharger and remove the four nuts (1).

NOTE: The turbocharger mounting nuts must be replaced.

47. Lift the manifold up and off of the turbocharger. Remove and discard the gasket.