Turbocharger — RH

Special Tool(s)

Spring Lock Coupling Disconnect Tool 310-S039 (T90T-9550-S) or equivalent

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

1. With the vehicle in NEUTRAL, position it on a hoist. Refer to Section 100-02 .

2. NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).

   Using a suitable holding device, hold the steering wheel in the straight-ahead position.

3. Remove the 4 retainers and the underbody shield.

4. Drain the cooling system. Refer to Section 303-03 .

5. Remove the RH catalytic converter. Refer to Section 309-00 .

6. Remove the front subframe. Refer to Section 502-00 .

7. Remove the RH turbocharger oil supply tube secondary latch.

8. Using a Spring Lock Coupling Disconnect Tool, remove the RH turbocharger oil supply tube from the quick connect fitting.
   • Inspect and if necessary, replace the quick connect fitting.

9. Loosen the clamp and remove the RH turbocharger intake pipe from the RH turbocharger.

10. Disconnect the turbocharger wastegate regulating valve hose from the RH turbocharger assembly.

11. Remove the 3 bolts and the RH turbocharger lower bracket.

12. Remove the 2 bolts and the RH turbocharger oil return tube from the turbocharger.
    • Remove and discard the gasket.

13. Remove the RH turbocharger oil return tube from the cylinder block.
    • Discard the 2 O-ring seals.

14. Remove the 2 coolant tube banjo bolts and the RH turbocharger coolant tubes.
    • Discard the sealing washers. Discard the specified component. Follow local disposal regulations.

15. Detach the 2 vacuum hose retainers from the strut tower brace.

16. Remove the 4 nuts and the strut tower brace.

17. Disconnect the LH turbocharger bypass valve electrical connector and the turbocharger bypass valve hose.

18. Remove the turbocharger wastegate regulating valve hose from the RH Charge Air Cooler (CAC) tube.

19. Disconnect the RH turbocharger bypass valve electrical connector.

20. Disconnect the RH turbocharger bypass valve hose.

21. Remove the RH CAC tube nut from the intake manifold.

22. Loosen the clamp and remove the RH CAC tube.

23. Loosen the clamp and remove the RH CAC tube from the RH turbocharger.

24. Remove the 5 bolts and the 2 upper RH exhaust manifold heat shields.

25. Remove the 2 bolts and the RH engine lifting eye.

26. Remove the 3 RH exhaust manifold-to-turbocharger bolts.
    • Discard the gasket.

27. Remove the upper RH turbocharger-to-cylinder block bracket bolt and the RH turbocharger assembly.

28. Remove the RH turbocharger oil supply tube banjo bolt.
    • Discard the sealing washer and oil supply tube filter.

Installation

1. Install the oil supply tube filter, washer and bolt.
   1. Install the new oil supply tube filter in the oil supply tube block.
   2. Slide the new washer onto the oil supply tube block.
   3. Install the bolt into the oil supply tube block.

2. Install the RH turbocharger oil supply tube.
   • Tighten the bolt to 40 Nm (30 lb-ft).

3. NOTICE: The upper RH turbocharger bracket bolts must be loosened in order to perform the tightening sequence or damage to the turbocharger may occur.

   Loosen the 2 bolts for the upper RH turbocharger-to-cylinder block bracket.

4. Install a new RH exhaust manifold-to-turbocharger gasket.

5. Install the RH turbocharger assembly and the upper RH turbocharger-to-cylinder block bracket bolt.
   • Do not tighten the bolts at this time.

6. Install the 3 new RH exhaust manifold-to-turbocharger bolts.
   • Tighten to 45 Nm (33 lb-ft).

7. Install the RH engine lifting eye and the 2 bolts.
   • Tighten to 24 Nm (18 lb-ft).

8. Install the 2 upper RH exhaust manifold heat shields and the 5 bolts.
   • Tighten to 12 Nm (106 lb-in).

9. NOTE: Align the index marks for the RH CAC tube.

   Install the RH CAC tube to the RH turbocharger and tighten the clamp.
   • Tighten to 5 Nm (44 lb-in).

10. NOTE: Align the index marks for the RH CAC tube.

    Install the RH CAC and tighten the clamp.
    • Tighten to 5 Nm (44 lb-in).

11. Install the RH CAC tube and the RH CAC tube nut to the intake manifold.
    • Tighten to 6 Nm (53 lb-in).

12. Connect the RH turbocharger bypass valve hose.

13. Connect the RH turbocharger bypass valve electrical connector.

14. Install the turbocharger wastegate regulating valve hose to the RH CAC tube.

15. Connect the LH turbocharger bypass valve electrical connector and the turbocharger bypass valve hose.

16. Install the strut tower brace and the 4 nuts.
    • Tighten to 30 Nm (22 lb-ft).

17. Attach the 2 brake booster vacuum hose retainers to the strut tower brace.

18. Position the upper RH turbocharger-to-cylinder block bracket as far clockwise as possible and tighten the bolts in the following sequence.
    1. Tighten the lower cylinder block bracket bolt to 26 Nm (19 lb-ft).
    2. Tighten the upper cylinder block bracket bolt to 26 Nm (19 lb-ft).
    3. Tighten the cylinder block bracket-to-turbocharger bolt to 19 Nm (168 lb-in).

19. Using 2 new sealing washers, install the 2 RH turbocharger coolant tube banjo bolts.
    • Tighten to 40 Nm (30 lb-ft).

20. NOTE: Lubricate the cylinder block bore with clean engine oil.

    Using 2 new O-ring seals, install the RH turbocharger oil return tube in the cylinder block.

21. Install a new gasket and install the RH turbocharger oil return tube and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).

22. Install the lower RH turbocharger bracket and the 3 bolts and tighten in sequence shown.
    1. Tighten the lower RH turbocharger bracket-to-turbocharger bolt to 19 Nm (168 lb-in).
    2. Tighten the 2 lower RH turbocharger bracket-to-cylinder block bolts to 48 Nm (35 lb-in).

23. NOTE: Make sure the turbocharger wastegate regulating valve hose does not contact the exhaust manifold heat shield.

    Connect the turbocharger wastegate regulating valve hose to the RH turbocharger.

24. NOTE: Align the index marks for the RH turbocharger intake pipe.

    Install the RH turbocharger intake pipe to the RH turbocharger and tighten the clamp.
    • Tighten to 5 Nm (44 lb-in).

25. NOTE: Listen for audible click when installing the oil supply tube into the quick connect fitting.

    Install the RH turbocharger oil supply tube into the quick connect fitting.

26. Install the RH turbocharger oil supply tube secondary latch.

27. Install the front subframe. Refer to Section 502-00 .

28. Install the RH catalytic converter. Refer to Section 309-00 .

29. Fill and bleed the cooling system. Refer to Section 303-03 .

30. Install the underbody shield and the 4 retainers.