GM Grand Am/Achieva/Calais/Skylark/Somerset 1985-98

Turbocharger

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REMOVAL & INSTALLATION



See Figure 1

The 2.0L engine is the only one equipped with a turbocharger.

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Properly drain the engine coolant.
  6.  
  7. Remove the lower fan attaching screw.
  8.  
  9. Disconnect the exhaust pipe.
  10.  
  11. Remove the bolt at the rear of the A/C compressor support bracket, then loosen the remaining bolts.
  12.  
  13. Remove turbocharger-to-engine support bracket.
  14.  
  15. Disconnect and plug the oil drain pipe at turbocharger.
  16.  
  17. Detach the water return pipe at turbocharger.
  18.  
  19. Carefully lower the vehicle.
  20.  
  21. Disconnect the coolant recovery pipe and position it to one side, out of the way.
  22.  
  23. Remove the air induction tube, coolant fan, and oxygen sensor.
  24.  
  25. Disconnect the oil and water feed pipes.
  26.  
  27. Detach the air intake duct and vacuum hose at the actuator.
  28.  
  29. Unfasten the exhaust manifold attaching nuts and remove turbocharger and exhaust manifold as an assembly.
  30.  
  31. Separate the turbocharger from the exhaust manifold.
  32.  



Click image to see an enlarged view

Fig. Fig. 1: View of the turbocharger mounting

To install:
  1. Assemble the turbocharger and exhaust manifold.
  2.  
  3. Clean the exhaust manifold and cylinder head mating surfaces.
  4.  
  5. Install a new gasket and install the manifold/turbocharger assembly to the engine. Tighten the Nos. 2 and 3 manifold runner nuts first, then Nos. 1 and 4, to 18 ft. lbs. (24 Nm).
  6.  
  7. Connect the oil and water feed and return lines.
  8.  
  9. Attach the oxygen sensor.
  10.  
  11. Connect the air intake duct and connect the vacuum hose to the actuator.
  12.  
  13. Install the and secure cooling fan.
  14.  
  15. Install the induction tube and coolant recovery tube.
  16.  
  17. Raise and safely support the vehicle.
  18.  
  19. Install the rear turbocharger support bolt.
  20.  
  21. Attach the compressor support bracket.
  22.  
  23. Install the oil drain hose.
  24.  
  25. Attach and secure the exhaust pipe.
  26.  
  27. Connect the negative battery cable. Check the turbocharger for proper operation and the assembly for leaks.
  28.  

 
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