Saab 2000-06

Turbocharger

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Removal & Installation



2.0L And 2.3L Engines
9-5 Models-2.3L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Lower front cover
     
    Loosen the oil return pipe from the turbocharger to the engine
     
    Oil pipe between the oil filter adapter and the turbocharger
     
    Bypass pipe and valve
     
    Control valve connector
     
    Mass Air Flow (MAF) sensor electrical connector
     
    Loosen the hoses to the turbocharger and diaphragm housing
     
    Crankcase breather pipe
     
    Engine lifting eye
     
    MAF sensor and air hose
     
    Exhaust manifold heat shield
     
    Quick release coupling on the vent hose
     
    Intake manifold V-clamp
     
    Intake manifold
     
    Hose between the turbocharger and the charge air cooler
     
    Exhaust system from the turbocharger
     
    Oil pipe from the oil filter adapter and copper washers
     
    Coolant pipe to the turbocharger
     
    Coolant return pipe from the cylinder head and the pressure sensor bracket
     
    Turbocharger and discard the gasket
     

  6.  

To install:

  1. Install or connect the following:

    Turbocharger with a new gasket and torque the 2 upper bolts to 18 ft. lbs. (24 Nm)
     
    Coolant return pipe with new copper washers and torque the nipple to 26 ft. lbs. (35 Nm), the banjo bolt to 19 ft. lbs. (25 Nm), the coolant return pipe to 19 ft. lbs. (25 Nm) and the coolant return pipe clamp to 7 ft. lbs. (9 Nm).
     
    Turbocharger oil pipe with new copper washers and torque the banjo bolt to 15 ft. lbs. (20 Nm)
     
    Turbocharger intake pipe with a new O-ring and loosen the adjusting screw on the intake manifold
     
    Torque the V clamp between the turbocharger to intake pipe to 2.5 ft. lbs. (4 Nm) and the intake manifold and adjusting screw to 18 ft. lbs. (24 Nm).
     
    Hoses to the turbocharger and diaphragm housing
     
    Charge air cooler inlet hose and torque the bolts to 6 ft. lbs. (8 Nm)
     
    Heat shield and torque the bolts to 15 ft. lbs. (20 Nm)
     
    MAF sensor and air hose
     
    Engine lifting eye
     
    Crankcase breather pipe and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Charge air bypass valve and pipe with a new O-ring and torque the bolts to 6 ft. lbs. (8 Nm)
     
    Lower nut to the turbo charger and torque the stud to 16 ft. lbs. (22 Nm) and the lock nut to 18 ft. lbs. (24 Nm)
     
    Turbocharger oil pipe with new copper washers and torque the bolt to 19 ft. lbs. (25 Nm)
     
    Turbocharger stays and torque to 18 ft. lbs. (24 Nm)
     
    Oil return pipe between the turbocharger and engine and torque the bolts to 10 ft. lbs. (15 Nm)
     
    Lower engine cover
     
    Negative battery cable
     

  2.  
  3. Fill the engine with coolant.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

9-5 Models-3.0L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Upper engine cover
     
    Turbocharger pressure hose with the bypass pipe and valve
     
    Exhaust manifold heat shield
     
    Crankcase breather pipe
     
    Turbocharger intake pipe
     
    Turbocharger outlet hose to the charge air cooler
     
    Radiator fan and clamp off the coolant hoses to the turbocharger
     
    Coolant pipes
     
    Front pipe from the turbocharger
     
    Oxygen (O 2 S) sensor electrical connector
     
    Front and rear exhaust systems
     
    Front pipe from the rear exhaust manifold
     
    Turbocharger oil return pipe
     
    Turbocharger mounting bracket
     
    Front exhaust manifold and turbocharger as an assembly

    Click image to see an enlarged view

    Fig. Remove the turbocharger and exhaust manifold as an assembly

     

  6.  

To install:

  1. Fill the turbo inlet with oil. Rotate the compressor wheel by hand several times to assure the bearings are well lubricated.
  2.  
  3. Install or connect the following:

    Turbocharger and exhaust manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Front pipe to the exhaust manifold with a new gasket and torque the bolts to 30 ft. lbs. (40 Nm)
     
    Pipe joint between the front and rear exhaust systems and torque the bolts to 16 ft. lbs. (22 Nm)
     
    O 2 S electrical connector
     
    Oil pipe to the oil filter adapter with new gaskets and sealing washers and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Turbocharger mounting bracket and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Oil return pipe and torque the bolts to 10 ft. lbs. (15 Nm)
     
    Front exhaust pipe to the turbocharger and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Coolant pipes with new sealing washers and torque the banjo bolt to 19 ft. lbs. (25 Nm) and the cylinder head retaining screw to 10 ft. lbs. (15 Nm)
     
    Radiator fan and unclamp the coolant hoses
     
    Hose between the turbocharger and charge air cooler and torque the fasteners to 6 ft. lbs. (8 Nm)
     
    Turbocharger intake pipe and torque the V clamp to 2 ft. lbs. (3 Nm) and the U clamp to 10 ft. lbs. (15 Nm)
     
    Crankcase breather pipe and torque the banjo bolt to 18 ft. lbs. (24 Nm)
     
    Exhaust manifold heat shield and torque the stud to 16 ft. lbs. (22 Nm) and the lock nut to 18 ft. lbs. (24 Nm)
     
    Turbocharger pressure hose with the bypass pipe and valve and torque to 6 ft. lbs. (8 Nm)
     
    Negative battery cable
     
    Engine upper cover
     

  4.  
  5. Fill the cooling system to the proper level.
  6.  
  7. Start the vehicle, check for leaks and repair if necessary.
  8.  

900 And 9-3 Models
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Hose from the charge air cooler
     
    Front exhaust pipe from the engine. Take care not to damage the Oxygen (O 2 S) Sensor electrical wiring harness.
     
    Locking ring on the wastegate after breaking the seal
     
    Oil return pipe from the turbocharger
     
    Oil pipe from the oil filter housing
     
    Hose to the boost control valve
     
    Nuts from the wastegate diaphragm
     
    Intake pipe and wastegate as a unit
     
    Intake pipe and the bypass hose
     
    Turbocharger coolant pipe with the oil pipe
     
    Turbocharger and discard the gasket
     

  6.  

To install:

  1. Install or connect the following:
    WARNING
    It is very important that there is oil in the turbocharger when the engine is started to avoid damage to the unit.



    Turbocharger with a new gasket and torque the nuts to 16 ft. lbs. (22 Nm) and fill the turbocharger interchamber passage with engine oil.
     



    Turbocharger coolant and oil pipes
     
    Intake pipe for the turbocharger
     
    Wastegate with the boost pressure control valve and pipes
     
    Intake hose with the bypass hose
     
    Locking ring and seal for the wastegate
     
    Front pipe to the turbocharger
     
    Hose connecting the charge air cooler with the turbocharger
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system and check the oil level.
  4.  
  5. Reseal the boost pressure control rod.
  6.  
  7. Test drive the vehicle for proper operation.
  8.  

9000 Models
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Center air deflector
     
    Top pipe coupling on the air-cooled oil cooler and the clips securing the pipe to the radiator
     
    Solenoid valve from its mounting on the radiator and the electrical leads
     
    Radiator fan
     
    Oxygen (O 2 S) sensor cable clamps
     
    Exhaust pipe from the turbocharger. Bend it down slightly
     
    Electrical connectors for the air mass meter
     
    Toggle fasteners securing the air mass meter to the air cleaner cover
     
    Rubber socket connector off the turbocharger unit
     
    Turbocharger pressure pipe from the turbocharger compressor
     
    Oil pipe to the turbocharger unit
     
    Clip securing the oil pipe to the cylinder head
     
    Oil pipe banjo coupling from the block
     
    Oil pipe clip on the intake manifold
     
    Coolant pipes from the turbocharger unit
     
    Steady bar bracket between the engine block and the turbocharger compressor
     
    Securing bolts to the oil return lines. Cap the opening to prevent washers or nuts from the exhaust manifold dropping inside during the removal.
     
    Turbocharger unit from the exhaust manifold and discard the gasket
     

  6.  

To install:

  1. Install or connect the following:
    WARNING
    Fill the turbocharger interchamber passage with engine oil. It is very important that there is oil in the turbocharger when the engine is started to avoid damage to the unit.



    Turbocharger unit on the exhaust manifold with a new gasket.Torque the new nuts to 16 ft. lbs. (22 Nm).
     



    Oil supply pipe clip to intake manifold
     
    Banjo coupling to the engine block. Be sure the copper washers are in good condition.
     
    Oil supply pipe to the turbocharger unit
     
    Return oil pipe and the steady bar bracket
     
    Rubber hangers for the front exhaust hanger
     
    Exhaust pipe to the turbocharger compressor with new locknuts. Lubricate the 3 studs on the turbocharger with Molykote 1000®. Torque the nuts to 19 ft. lbs. (25 Nm).
     
    Coolant pipes to the turbocharger
     
    Turbocharger pressure pipe to the turbocharger compressor
     
    Air mass meter and rubber socket connector between the air cleaner body and the inlet side of the turbocharger compressor
     
    Radiator solenoid valve and secure the electrical leads into their clips
     
    Return hose to the solenoid valve
     
    Oil pipe to the oil cooler and secure the pipe clip to the radiator
     
    Radiator drain plug
     
    Center air deflector
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Check the oil level and top off if necessary.
  6.  
  7. Start the vehicle, check for leaks and repair if necessary.
  8.  

9-3
(2001-02)
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following: Negative battery cableTurbocharger stay and front exhaust pipe stayCoolant pipe from turbochargerOil return pipe from the turbocharger (plug openings)Oil pipe from the oil filter housingTurbocharger outlet hose from charge air cooler (plug openings)Hose between MAF sensor and turbocharger inlet pipeBypass pipe with valve (keep O-ring)Exhaust manifold heat shieldSolenoid valve connector and hosesCrankcase vent pipe from turbocharger inlet pipe and camshaft cover (move pipe aside)EVAP purge hose from T-connector on solenoid valveEngine lifting eyeTurbocharger inlet pipeTop 2 nuts on joint between turbocharger and front exhaust pipe (move exhaust pipe aside)

    Negative battery cable
     
    Turbocharger stay and front exhaust pipe stay
     
    Coolant pipe from turbocharger
     
    Oil return pipe from the turbocharger (plug openings)
     
    Oil pipe from the oil filter housing
     
    Turbocharger outlet hose from charge air cooler (plug openings)
     
    Hose between MAF sensor and turbocharger inlet pipe
     
    Bypass pipe with valve (keep O-ring)
     
    Exhaust manifold heat shield
     
    Solenoid valve connector and hoses
     
    Crankcase vent pipe from turbocharger inlet pipe and camshaft cover (move pipe aside)
     
    EVAP purge hose from T-connector on solenoid valve
     
    Engine lifting eye
     
    Turbocharger inlet pipe
     
    Top 2 nuts on joint between turbocharger and front exhaust pipe (move exhaust pipe aside)
     

  6.  


CAUTION
DO NOT bend bellows on exhaust pipe more than 5degrees or bellows will be permanently deformed.



Wastegate (2 bolts and 1 clip)
 
Oil pipe from turbocharger
 
Transverse coolant pipe from cylinder head and from pressure sensor mounting
 
Coolant hose from water pump and turbocharger
 
Turbocharger-to-exhaust manifold nuts
 
Turbocharger (lower from car)
 

To install:

  1. Install or connect the following: Turbocharger (from below) with a new gasket and torque the nuts to 18 ft. lbs. (24 Nm) and fill the turbocharger interchamber passage with engine oil

    Turbocharger (from below) with a new gasket and torque the nuts to 18 ft. lbs. (24 Nm) and fill the turbocharger interchamber passage with engine oil
     

  2.  


WARNING
It is very important that there is oil in the turbocharger when the engine is started to avoid damage to the unit.



Coolant pipe with new banjo bolt and new gaskets to cylinder head and pressure sensor mounting; torque to 18 ft. lbs. (25 Nm)
 
Turbocharger coolant pipe from water pump
 
Wastegate (2 bolts and 1 clip)
 
Exhaust pipe to joint mount with turbocharger; torque nuts, in alternating pattern, to 18 ft. lbs. (24 Nm)
 


CAUTION
DO NOT allow exhaust pipe flange to contact turbocharger flange.



Turbocharger inlet pipe with O-rings; do not tighten V-clamp
 
Hoses to solenoid valve
 
Engine lifting eye
 
Tighten inlet pipe V-clamp
 
EVAP purge hose to T-connection
 
Crankcase vent pipe to turbocharger inlet pipe with new sealing washers torqued to 18 ft. lbs. (24 Nm)
 
Fasten crankcase vent pipe to camshaft cover
 
Exhaust manifold heat shield
 
Bypass pipe and valve, with new O-ring, to inlet pipe; torque to 6 ft. lbs. (8 Nm)
 


WARNING
To reduce risk of turbocharger hoses coming loose under pressure, be sure fittings and inside of hoses are cleaned before connections are made.



Connecting hose between MAF sensor and turbocharger inlet pipe
 
Solenoid valve connector
 
Hose connecting the charge air cooler with the turbocharger
 
Oil pipe from turbocharger to oil filter adapter, with new copper washers, torqued to 18 ft. lbs. (25 Nm)
 


NOTE
Make sure oil pipe connection is straight when tightened.



Oil return pipe from turbocharger to cylinder block
 
Coolant pipe of turbocharger with new sealing washers and torque to 18 ft. lbs. (25 Nm)
 
Bottom nut on joint between turbocharger and front exhaust pipe torqued to 18 ft. lbs. (25 Nm)
 
Negative battery cable
 

  1. Fill cooling system and bleed by starting engine (A/C off) and running at varying speeds until the cooling fan comes on. Turn engine off and top up coolant in expansion tank.
  2.  
  3. Check for leaks.
  4.  

(2003-04)
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove expansion tank cap to release any pressure.
  4.  
  5. Remove or disconnect the following: Upper oxygen sensor and temperature sensor connectorsCrankcase vent hose from camshaft cover and turbocharger inlet (B207L)Air cleaner housing and turbo inlet hoseHose to crankcase ventilation and secondary air injection (SAI) hose (B205R)Turbocharger heat shieldSolenoid valve hoses from turbocharger (B205R)Pipe connection for crankcase ventilation (B205R)Locking clip from turbocharger control armVacuum unit from turbochargerHose from turbocharger bypass (B205R)Upper oxygen sensorCatalytic converter connection from turbochargerFront spoiler shieldDrain the cooling system (radiator and water pump)Coolant pipe from turbocharger and cylinder head (grip inner connection so it does not come off turbo)Oil pipe from turbochargerLower pressure pipe from turbochargerFront exhaust pipe from catalytic converterSteering gear heat shieldCatalytic converter heat shieldTemperature sensorLower oxygen sensorCatalytic converter retainer from engine blockCatalytic converterCoolant pipe from turbocharger and thermostat housingOil return pipe from turbocharger and engine block (collect O-ring)Stay between engine block and turbocharger (B205R)Oil pressure pipe from engine blockTurbocharger from bottom of car

    Upper oxygen sensor and temperature sensor connectors
     
    Crankcase vent hose from camshaft cover and turbocharger inlet (B207L)
     
    Air cleaner housing and turbo inlet hose
     
    Hose to crankcase ventilation and secondary air injection (SAI) hose (B205R)
     
    Turbocharger heat shield
     
    Solenoid valve hoses from turbocharger (B205R)
     
    Pipe connection for crankcase ventilation (B205R)
     
    Locking clip from turbocharger control arm
     
    Vacuum unit from turbocharger
     
    Hose from turbocharger bypass (B205R)
     
    Upper oxygen sensor
     
    Catalytic converter connection from turbocharger
     
    Front spoiler shield
     
    Drain the cooling system (radiator and water pump)
     
    Coolant pipe from turbocharger and cylinder head (grip inner connection so it does not come off turbo)
     
    Oil pipe from turbocharger
     
    Lower pressure pipe from turbocharger
     
    Front exhaust pipe from catalytic converter
     
    Steering gear heat shield
     
    Catalytic converter heat shield
     
    Temperature sensor
     
    Lower oxygen sensor
     
    Catalytic converter retainer from engine block
     
    Catalytic converter
     
    Coolant pipe from turbocharger and thermostat housing
     
    Oil return pipe from turbocharger and engine block (collect O-ring)
     
    Stay between engine block and turbocharger (B205R)
     
    Oil pressure pipe from engine block
     
    Turbocharger from bottom of car
     

  6.  

To install:

  1. Install a new gasket for turbocharger.
  2.  
  3. Coat turbocharger stud bolts and exhaust manifold stud bolts with thread paste.
  4.  
  5. Raise and position turbocharger to engine. Tighten mounting stud bolts to 18 ft. lbs. (24 Nm).
  6.  
  7. Install or connect the following: Oil return pipe to turbocharger, with new gasket and O-ring; torque to 11 ft. lbs. (15 Nm).Coolant pipe between turbocharger and thermostat housing, with new sealing washers; torque to 15 ft. lbs. (20 Nm)Bolt, with new sealing washers, for turbocharger oil delivery pipe on engine block; do not tightenStay between turbocharger and engine block torqued to 24 ft. lbs. (32 Nm) for bolt in turbocharger and 35 ft. lbs. (48 Nm) for M10 boltFill turbocharger oil delivery connection with clean engine oil while turning turbine wheelOil delivery pipe to turbocharger and tighten connection, with new sealing washers; torque to 21 ft. lbs. (28 Nm)Coolant pipe to turbocharger and pipe mounting on cylinder headHose to bypass valveOil delivery pipe connection on engine block (from under car); torque to 21 ft. lbs. (28 Nm)

    Oil return pipe to turbocharger, with new gasket and O-ring; torque to 11 ft. lbs. (15 Nm).
     
    Coolant pipe between turbocharger and thermostat housing, with new sealing washers; torque to 15 ft. lbs. (20 Nm)
     
    Bolt, with new sealing washers, for turbocharger oil delivery pipe on engine block; do not tighten
     
    Stay between turbocharger and engine block torqued to 24 ft. lbs. (32 Nm) for bolt in turbocharger and 35 ft. lbs. (48 Nm) for M10 bolt
     
    Fill turbocharger oil delivery connection with clean engine oil while turning turbine wheel
     
    Oil delivery pipe to turbocharger and tighten connection, with new sealing washers; torque to 21 ft. lbs. (28 Nm)
     
    Coolant pipe to turbocharger and pipe mounting on cylinder head
     
    Hose to bypass valve
     
    Oil delivery pipe connection on engine block (from under car); torque to 21 ft. lbs. (28 Nm)
     

  8.  
  9. Position the catalytic converter with new nuts on studs to 7 ft. lbs. (10 Nm). Ensure converter rests against turbocharger.
  10.  
  11. Raise the car and tighten the catalytic converter nuts to 18 ft. lbs. (25 Nm) and bolts to 16 ft. lbs. (22 Nm) a last time.
  12.  
  13. Lightly coat threads of lower oxygen sensor with thread paste and install sensor. Torque it to 30 ft. lbs. (40 Nm). Be sure oxygen sensor cables are not twisted or damaged.
  14.  
  15. Lightly coat threads of temperature sensor with thread paste and install sensor. Tighten to 33 ft. lbs. (45 Nm). Check to be sure all wiring from oxygen sensor and temperature sensor is not twisted or damaged.
  16.  
  17. Install or connect the following: Catalytic converter heat shieldSteering gear heat shieldCatalytic converter and pipe to front muffler; torque joint of converter to 19 ft. lbs. (25 Nm) and joint clamp nuts to 30 ft. lbs. (40 Nm)Turbocharger delivery pipeRadiator drain cockFront spoiler shieldUpper oxygen sensor (threads coated lightly with thread paste); torque sensor to 30 ft. lbs. (40 Nm)Oxygen sensor and temperature sensor connectorsVacuum unit to turbochargerControl rod to control armPipe for crankcase ventilation (B205R)Control valve hoses to turbochargerTurbocharger heat shield

    Catalytic converter heat shield
     
    Steering gear heat shield
     
    Catalytic converter and pipe to front muffler; torque joint of converter to 19 ft. lbs. (25 Nm) and joint clamp nuts to 30 ft. lbs. (40 Nm)
     
    Turbocharger delivery pipe
     
    Radiator drain cock
     
    Front spoiler shield
     
    Upper oxygen sensor (threads coated lightly with thread paste); torque sensor to 30 ft. lbs. (40 Nm)
     
    Oxygen sensor and temperature sensor connectors
     
    Vacuum unit to turbocharger
     
    Control rod to control arm
     
    Pipe for crankcase ventilation (B205R)
     
    Control valve hoses to turbocharger
     
    Turbocharger heat shield
     

  18.  


WARNING
To reduce the risk that turbocharger hoses will come loose under pressure, thoroughly clean all fittings and inside of hoses before connecting.



Air cleaner housing and turbocharger inlet hose
 
Crankcase vent hose to camshaft cover and turbocharger and hose from solenoid valve
 
Negative battery cable
 

  1. Fill cooling system and bleed by starting engine (A/C off) and running at varying speeds until the cooling fan comes on. Turn engine off and top up coolant in expansion tank.
  2.  
  3. Check for leaks.
  4.  

2.8L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove lower front cover and drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Battery and engine covers
     
    Battery cable
     
    Expansion tank cap
     

  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Remove the chassis reinforcement, front sub-frame (convertible)
  10.  
  11. Remove the front nuts of the rear catalytic converter and move aside. Fix in position with 83 95 212 Strap.
  12.  
  13. Remove the mounting from the front catalytic converter and oil sump using 32 025 061 Crow foot wrench.
  14.  
  15. Lower the vehicle.
  16.  
  17. Remove the battery and battery cover bottom.
  18.  
  19. Detach the breather hoses from the coolant reservoir.
  20.  
  21. Detach the breather pipe from the turbocharger and heat shield.
  22.  
  23. Detach and raise the expansion tank slightly.
  24.  
  25. Detach the lower hose of the coolant reservoir, unplug the level sensor connector and lift away the coolant reservoir.
  26.  
  27. Remove the upper heat shield from the turbocharger.
  28.  
  29. Remove the bolt of the ventilation pipe mounting.
  30.  
  31. Unplug the upper oxygen sensor connector and remove the cable fixings. Move the cable up.
  32.  
  33. Carefully raise the heat shield slightly. Use an oxygen sensor socket to remove the oxygen sensor.
  34.  
  35. Remove the turbocharger's lower heat shield.
  36.  
  37. Remove the bolt of the catalytic converter mounting.
  38.  
  39. Remove the catalytic converter nuts to the turbocharger. Lubricate the studs and nuts with rust removal oil and carefully loosen.
  40.  
  41. Remove the upper radiator member (B284E).
  42.  
  43. Unplug the mass air flow sensor connector. Detach the secondary air pipe, the delivery hose from the turbocharger intake manifold and the crankcase ventilation pipes.
  44.  
  45. Detach the turbocharger intake manifold from the air cleaner casing cover and the turbocharger.
  46.  
  47. Remove the bypass valve and unplug the connector.
  48.  
  49. Remove the upper radiator mounting.
  50.  
  51. Unplug the radiator fan connectors and detach the wiring harness from the fan cowling.
  52.  
  53. Remove the bolts of the lower turbocharger delivery pipe and the fan cowling.
  54.  
  55. Press the radiator assembly forward and remove the fan cowling.
  56.  
  57. Detach the intake manifold of the secondary air injection pump from the pump.
  58.  
  59. Detach the discharge pipe of the secondary air injection pump from the pump.
  60.  
  61. Unplug the intake air sensor connector (688).
  62.  
  63. Detach the upper turbocharger delivery pipe.
  64.  
  65. Remove the screw holding the dipstick tube.
  66.  
  67. Remove the heat shield of the front exhaust manifold. Lubricate the studs and nuts with rust removal oil and carefully loosen.
  68.  
  69. Detach the intermediate exhaust pipe from the turbocharger and the front exhaust manifold.
  70.  
  71. Detach the vacuum hoses and crankcase ventilation pipe from the turbocharger.
  72.  
  73. Detach the lower turbocharger delivery hose from the turbocharger.
  74.  
  75. Detach the oil delivery pipe from the engine.
  76.  
  77. Remove the oil return pipe from the turbocharger.
  78.  
  79. Remove the oil delivery pipe's banjo screws from the turbocharger.
  80.  
  81. Remove the coolant pipe's banjo screw from the turbocharger.
  82.  
  83. Remove the nuts of the rear intermediate exhaust pipe.
  84.  
  85. Remove the bolt holding the turbocharger to the bracket. Use an impact socket and a long puller.
  86.  
  87. Remove the turbocharger.
  88.  

To install:


NOTE
It is essential that there is oil in the turbocharger bearing housing when the engine is started, especially after a new turbocharger has been fitted.

  1. Fill the turbocharger's oil inlet with oil from an oilcan. Rotate the compressor wheel by hand a number times to ensure that oil enters the bearings.
  2.  
  3. Position the turbocharger and install the bolt that holds the turbocharger to the bracket. Tighten the turbocharger-to-bracket bolt to 48 ft. lbs. (65 Nm).
  4.  
  5. Install the nuts of the rear intermediate exhaust pipe. Tighten alternately to 22 ft. lbs. (30 Nm). The conical side of the nut should face the center exhaust pipe.
  6.  
  7. Install the coolant pipe's banjo screw to the turbocharger. Use new gaskets and tighten the banjo screw to 22 ft. lbs. (30 Nm).
  8.  
  9. Install the oil delivery pipe's banjo screws to the turbocharger using new gaskets. Tighten the banjo screws to 22 ft. lbs. (30 Nm).
  10.  
  11. Connect the oil return pipe to the turbocharger using new gaskets. Tighten the fasteners to 10 ft. lbs. (14 Nm).
  12.  
  13. Attach the oil delivery pipe to the engine using new gaskets. Tighten the fasteners to 22 ft. lbs. (30 Nm).
  14.  
  15. To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressure, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 93 160 907 Motip Dupli cleaning agent to wipe clean inside the ends of the hoses. Clean the connecting pieces as well. If hose clips are rusty or damaged, they must be replaced so the correct clamping force is maintained.
  16.  
  17. Attach the lower turbocharger delivery hose to the turbocharger.
  18.  
  19. Attach the vacuum hoses and crankcase ventilation pipes to the turbocharger.
  20.  
  21. Attach the intermediate exhaust pipe to the front exhaust manifold and the turbocharger. Use a new gasket and coat the studs with 90 513 210 Universal paste. The conical side of the nut should face the center exhaust pipe.
  22.  
  23. Tighten the nuts first on the exhaust manifold and then on the turbocharger to 22 ft. lbs. (30 Nm). Tightening order 11a, 11b, 11c, and 11d alternating on the turbocharger. The surfaces should align with one another when the nuts are fitted. Check using a feeler gauge. If the surfaces are not flat or the pipe is deformed, the center exhaust pipe and/or exhaust manifold must be replaced.
  24.  
  25. Install the heat shield of the front exhaust manifold and tighten the fasteners to 7 ft. lbs. (10 Nm).
  26.  
  27. Install the screw holding the dipstick tube and tighten to 7 ft. lbs. (10 Nm).
  28.  
  29. Connect the upper turbocharger delivery pipe.
  30.  
  31. Plug in the intake air sensor connector (688).
  32.  
  33. Connect the discharge pipe of the secondary air injection pump.
  34.  
  35. Connect the secondary air injection pump's intake manifold to the pump.
  36.  
  37. Press the radiator assembly forward and position the fan cowling.
  38.  
  39. Install the bolts of the lower turbocharger delivery pipe and the fan cowling.
  40.  
  41. Plug in the radiator fan connectors and attach the wiring harness to the fan cowling.
  42.  
  43. Fit the upper radiator mounting.
  44.  
  45. Fit the bypass valve and plug in the connector.
  46.  
  47. Attach the turbocharger intake manifold to the turbocharger and the air cleaner casing cover.
  48.  
  49. Plug in the mass air flow sensor connector. Attach the secondary air pipe, the delivery hose to the turbocharger intake manifold and the crankcase ventilation pipes.
  50.  
  51. Install the upper radiator member (B284E).
  52.  
  53. Install the catalytic converter nuts to the turbocharger. Coat the studs with 90 513 210 Universal paste. When installing the front catalytic converter to the turbocharger, tighten the nuts in a crosswise pattern to avoid tightening the flange crooked. Tighten the nuts to 18 ft. lbs. (25 Nm).
  54.  
  55. Install the bolt of the catalytic converter mounting.
  56.  
  57. Install the turbocharger's lower heat shield.
  58.  
  59. Lightly coat the threads of the front oxygen sensor with 90 513 210 Universal paste and install using the proper socket. Tighten the oxygen sensor to 33 ft. lbs. (45 Nm).
  60.  
  61. Carefully press down the heat shield.
  62.  
  63. Secure the cable and plug in the connector.
  64.  
  65. Fit the bolt of the ventilation pipe mounting.
  66.  
  67. Fit the upper heat shield to the turbocharger.
  68.  
  69. Attach the lower hose of the coolant reservoir and plug in the level sensor connector.
  70.  
  71. Install the coolant reservoir in the mounting.
  72.  
  73. Attach the breather pipe to the turbocharger and heat shield. Use a new gasket. Tighten the banjo screw to 22 ft. lbs. (30 Nm).
  74.  
  75. Attach the breather hoses to the coolant reservoir.
  76.  
  77. Install battery cover bottom.
  78.  
  79. Install the battery.
  80.  
  81. Raise and safely support the vehicle.
  82.  
  83. Install the mounting on the front catalytic converter and oil sump.
  84.  
  85. Install the rear catalytic converter using a new gasket. Tighten the bolts to 18 ft. lbs. (25 Nm).
  86.  
  87. Install the chassis reinforcement, front sub-frame (convertible).
  88.  
  89. Lower the vehicle.
  90.  
  91. Refill the cooling system. Bleed and pressure test the cooling system.
  92.  
  93. Check the oil level and top off as necessary.
  94.  
  95. Connect the negative battery cable.
  96.  
  97. Install the battery cover and the engine cover.
  98.  
  99. Remove the wing covers and restore car electrical functions.
  100.  
  101. Start the engine and check for any exhaust, oil and coolant leakage.
  102.  

2000-2002 Model
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:
    CAUTION
    DO NOT bend bellows on exhaust pipe more than 5degrees or bellows will be permanently deformed.



    Negative battery cable
     
    Turbocharger stay and front exhaust pipe stay
     
    Coolant pipe from turbocharger
     
    Oil return pipe from the turbocharger (plug openings)
     
    Oil pipe from the oil filter housing
     
    Turbocharger outlet hose from charge air cooler (plug openings)
     
    Hose between MAF sensor and turbocharger inlet pipe
     
    Bypass pipe with valve (keep O-ring)
     
    Exhaust manifold heat shield
     
    Solenoid valve connector and hoses
     
    Crankcase vent pipe from turbocharger inlet pipe and camshaft cover (move pipe aside)
     
    EVAP purge hose from T-connector on solenoid valve
     
    Engine lifting eye
     
    Turbocharger inlet pipe
     
    Top 2 nuts on joint between turbocharger and front exhaust pipe (move exhaust pipe aside)
     



    Wastegate (2 bolts and 1 clip)
     
    Oil pipe from turbocharger
     
    Transverse coolant pipe from cylinder head and from pressure sensor mounting
     
    Coolant hose from water pump and turbocharger
     
    Turbocharger-to-exhaust manifold nuts
     
    Turbocharger (lower from car)
     

  6.  

To install:

  1. Install or connect the following:
    WARNING
    It is very important that there is oil in the turbocharger when the engine is started to avoid damage to the unit.


    CAUTION
    DO NOT allow exhaust pipe flange to contact turbocharger flange.


    WARNING
    To reduce risk of turbocharger hoses coming loose under pressure, be sure fittings and inside of hoses are cleaned before connections are made.


    NOTE
    Make sure oil pipe connection is straight when tightened.



    Turbocharger (from below) with a new gasket and torque the nuts to 18 ft. lbs. (24 Nm) and fill the turbocharger interchamber passage with engine oil
     



    Coolant pipe with new banjo bolt and new gaskets to cylinder head and pressure sensor mounting; torque to 18 ft. lbs. (25 Nm)
     
    Turbocharger coolant pipe from water pump
     
    Wastegate (2 bolts and 1 clip)
     
    Exhaust pipe to joint mount with turbocharger; torque nuts, in alternating pattern, to 18 ft. lbs. (24 Nm)
     



    Turbocharger inlet pipe with O-rings; do not tighten V-clamp
     
    Hoses to solenoid valve
     
    Engine lifting eye
     
    Tighten inlet pipe V-clamp
     
    EVAP purge hose to T-connection
     
    Crankcase vent pipe to turbocharger inlet pipe with new sealing washers torqued to 18 ft. lbs. (24 Nm)
     
    Fasten crankcase vent pipe to camshaft cover
     
    Exhaust manifold heat shield
     
    Bypass pipe and valve, with new O-ring, to inlet pipe; torque to 6 ft. lbs. (8 Nm)
     



    Connecting hose between MAF sensor and turbocharger inlet pipe
     
    Solenoid valve connector
     
    Hose connecting the charge air cooler with the turbocharger
     
    Oil pipe from turbocharger to oil filter adapter, with new copper washers, torqued to 18 ft. lbs. (25 Nm)
     



    Oil return pipe from turbocharger to cylinder block
     
    Coolant pipe of turbocharger with new sealing washers and torque to 18 ft. lbs. (25 Nm)
     
    Bottom nut on joint between turbocharger and front exhaust pipe torqued to 18 ft. lbs. (25 Nm)
     
    Negative battery cable
     

  2.  
  3. Fill cooling system and bleed by starting engine (A/C off) and running at varying speeds until the cooling fan comes on. Turn engine off and top up coolant in expansion tank.
  4.  
  5. Check for leaks.
  6.  

2001-02
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following: Negative battery cableTurbocharger stay and front exhaust pipe stayCoolant pipe from turbochargerOil return pipe from the turbocharger (plug openings)Oil pipe from the oil filter housingTurbocharger outlet hose from charge air cooler (plug openings)Hose between MAF sensor and turbocharger inlet pipeBypass pipe with valve (keep O-ring)Exhaust manifold heat shieldSolenoid valve connector and hosesCrankcase vent pipe from turbocharger inlet pipe and camshaft cover (move pipe aside)EVAP purge hose from T-connector on solenoid valveEngine lifting eyeTurbocharger inlet pipeTop 2 nuts on joint between turbocharger and front exhaust pipe (move exhaust pipe aside)

    Negative battery cable
     
    Turbocharger stay and front exhaust pipe stay
     
    Coolant pipe from turbocharger
     
    Oil return pipe from the turbocharger (plug openings)
     
    Oil pipe from the oil filter housing
     
    Turbocharger outlet hose from charge air cooler (plug openings)
     
    Hose between MAF sensor and turbocharger inlet pipe
     
    Bypass pipe with valve (keep O-ring)
     
    Exhaust manifold heat shield
     
    Solenoid valve connector and hoses
     
    Crankcase vent pipe from turbocharger inlet pipe and camshaft cover (move pipe aside)
     
    EVAP purge hose from T-connector on solenoid valve
     
    Engine lifting eye
     
    Turbocharger inlet pipe
     
    Top 2 nuts on joint between turbocharger and front exhaust pipe (move exhaust pipe aside)
     

  6.  


CAUTION
DO NOT bend bellows on exhaust pipe more than 5degrees or bellows will be permanently deformed.



Wastegate (2 bolts and 1 clip)
 
Oil pipe from turbocharger
 
Transverse coolant pipe from cylinder head and from pressure sensor mounting
 
Coolant hose from water pump and turbocharger
 
Turbocharger-to-exhaust manifold nuts
 
Turbocharger (lower from car)
 

To install:

  1. Install or connect the following: Turbocharger (from below) with a new gasket and torque the nuts to 18 ft. lbs. (24 Nm) and fill the turbocharger interchamber passage with engine oil

    Turbocharger (from below) with a new gasket and torque the nuts to 18 ft. lbs. (24 Nm) and fill the turbocharger interchamber passage with engine oil
     

  2.  


WARNING
It is very important that there is oil in the turbocharger when the engine is started to avoid damage to the unit.



Coolant pipe with new banjo bolt and new gaskets to cylinder head and pressure sensor mounting; torque to 18 ft. lbs. (25 Nm)
 
Turbocharger coolant pipe from water pump
 
Wastegate (2 bolts and 1 clip)
 
Exhaust pipe to joint mount with turbocharger; torque nuts, in alternating pattern, to 18 ft. lbs. (24 Nm)
 


CAUTION
DO NOT allow exhaust pipe flange to contact turbocharger flange.



Turbocharger inlet pipe with O-rings; do not tighten V-clamp
 
Hoses to solenoid valve
 
Engine lifting eye
 
Tighten inlet pipe V-clamp
 
EVAP purge hose to T-connection
 
Crankcase vent pipe to turbocharger inlet pipe with new sealing washers torqued to 18 ft. lbs. (24 Nm)
 
Fasten crankcase vent pipe to camshaft cover
 
Exhaust manifold heat shield
 
Bypass pipe and valve, with new O-ring, to inlet pipe; torque to 6 ft. lbs. (8 Nm)
 


WARNING
To reduce risk of turbocharger hoses coming loose under pressure, be sure fittings and inside of hoses are cleaned before connections are made.



Connecting hose between MAF sensor and turbocharger inlet pipe
 
Solenoid valve connector
 
Hose connecting the charge air cooler with the turbocharger
 
Oil pipe from turbocharger to oil filter adapter, with new copper washers, torqued to 18 ft. lbs. (25 Nm)
 


NOTE
Make sure oil pipe connection is straight when tightened.



Oil return pipe from turbocharger to cylinder block
 
Coolant pipe of turbocharger with new sealing washers and torque to 18 ft. lbs. (25 Nm)
 
Bottom nut on joint between turbocharger and front exhaust pipe torqued to 18 ft. lbs. (25 Nm)
 
Negative battery cable
 

  1. Fill cooling system and bleed by starting engine (A/C off) and running at varying speeds until the cooling fan comes on. Turn engine off and top up coolant in expansion tank.
  2.  
  3. Check for leaks.
  4.  

2003-04
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove expansion tank cap to release any pressure.
  4.  
  5. Remove or disconnect the following: Upper oxygen sensor and temperature sensor connectorsCrankcase vent hose from camshaft cover and turbocharger inlet (B207L)Air cleaner housing and turbo inlet hoseHose to crankcase ventilation and secondary air injection (SAI) hose (B205R)Turbocharger heat shieldSolenoid valve hoses from turbocharger (B205R)Pipe connection for crankcase ventilation (B205R)Locking clip from turbocharger control armVacuum unit from turbochargerHose from turbocharger bypass (B205R)Upper oxygen sensorCatalytic converter connection from turbochargerFront spoiler shieldDrain the cooling system (radiator and water pump)Coolant pipe from turbocharger and cylinder head (grip inner connection so it does not come off turbo)Oil pipe from turbochargerLower pressure pipe from turbochargerFront exhaust pipe from catalytic converterSteering gear heat shieldCatalytic converter heat shieldTemperature sensorLower oxygen sensorCatalytic converter retainer from engine blockCatalytic converterCoolant pipe from turbocharger and thermostat housingOil return pipe from turbocharger and engine block (collect O-ring)Stay between engine block and turbocharger (B205R)Oil pressure pipe from engine blockTurbocharger from bottom of car

    Upper oxygen sensor and temperature sensor connectors
     
    Crankcase vent hose from camshaft cover and turbocharger inlet (B207L)
     
    Air cleaner housing and turbo inlet hose
     
    Hose to crankcase ventilation and secondary air injection (SAI) hose (B205R)
     
    Turbocharger heat shield
     
    Solenoid valve hoses from turbocharger (B205R)
     
    Pipe connection for crankcase ventilation (B205R)
     
    Locking clip from turbocharger control arm
     
    Vacuum unit from turbocharger
     
    Hose from turbocharger bypass (B205R)
     
    Upper oxygen sensor
     
    Catalytic converter connection from turbocharger
     
    Front spoiler shield
     
    Drain the cooling system (radiator and water pump)
     
    Coolant pipe from turbocharger and cylinder head (grip inner connection so it does not come off turbo)
     
    Oil pipe from turbocharger
     
    Lower pressure pipe from turbocharger
     
    Front exhaust pipe from catalytic converter
     
    Steering gear heat shield
     
    Catalytic converter heat shield
     
    Temperature sensor
     
    Lower oxygen sensor
     
    Catalytic converter retainer from engine block
     
    Catalytic converter
     
    Coolant pipe from turbocharger and thermostat housing
     
    Oil return pipe from turbocharger and engine block (collect O-ring)
     
    Stay between engine block and turbocharger (B205R)
     
    Oil pressure pipe from engine block
     
    Turbocharger from bottom of car
     

  6.  

To install:

  1. Install a new gasket for turbocharger.
  2.  
  3. Coat turbocharger stud bolts and exhaust manifold stud bolts with thread paste.
  4.  
  5. Raise and position turbocharger to engine. Tighten mounting stud bolts to 18 ft. lbs. (24 Nm).
  6.  
  7. Install or connect the following: Oil return pipe to turbocharger, with new gasket and O-ring; torque to 11 ft. lbs. (15 Nm).Coolant pipe between turbocharger and thermostat housing, with new sealing washers; torque to 15 ft. lbs. (20 Nm)Bolt, with new sealing washers, for turbocharger oil delivery pipe on engine block; do not tightenStay between turbocharger and engine block torqued to 24 ft. lbs. (32 Nm) for bolt in turbocharger and 35 ft. lbs. (48 Nm) for M10 boltFill turbocharger oil delivery connection with clean engine oil while turning turbine wheelOil delivery pipe to turbocharger and tighten connection, with new sealing washers; torque to 21 ft. lbs. (28 Nm)Coolant pipe to turbocharger and pipe mounting on cylinder headHose to bypass valveOil delivery pipe connection on engine block (from under car); torque to 21 ft. lbs. (28 Nm)

    Oil return pipe to turbocharger, with new gasket and O-ring; torque to 11 ft. lbs. (15 Nm).
     
    Coolant pipe between turbocharger and thermostat housing, with new sealing washers; torque to 15 ft. lbs. (20 Nm)
     
    Bolt, with new sealing washers, for turbocharger oil delivery pipe on engine block; do not tighten
     
    Stay between turbocharger and engine block torqued to 24 ft. lbs. (32 Nm) for bolt in turbocharger and 35 ft. lbs. (48 Nm) for M10 bolt
     
    Fill turbocharger oil delivery connection with clean engine oil while turning turbine wheel
     
    Oil delivery pipe to turbocharger and tighten connection, with new sealing washers; torque to 21 ft. lbs. (28 Nm)
     
    Coolant pipe to turbocharger and pipe mounting on cylinder head
     
    Hose to bypass valve
     
    Oil delivery pipe connection on engine block (from under car); torque to 21 ft. lbs. (28 Nm)
     

  8.  
  9. Position the catalytic converter with new nuts on studs to 7 ft. lbs. (10 Nm). Ensure converter rests against turbocharger.
  10.  
  11. Raise the car and tighten the catalytic converter nuts to 18 ft. lbs. (25 Nm) and bolts to 16 ft. lbs. (22 Nm) a last time.
  12.  
  13. Lightly coat threads of lower oxygen sensor with thread paste and install sensor. Torque it to 30 ft. lbs. (40 Nm). Be sure oxygen sensor cables are not twisted or damaged.
  14.  
  15. Lightly coat threads of temperature sensor with thread paste and install sensor. Tighten to 33 ft. lbs. (45 Nm). Check to be sure all wiring from oxygen sensor and temperature sensor is not twisted or damaged.
  16.  
  17. Install or connect the following: Catalytic converter heat shieldSteering gear heat shieldCatalytic converter and pipe to front muffler; torque joint of converter to 19 ft. lbs. (25 Nm) and joint clamp nuts to 30 ft. lbs. (40 Nm)Turbocharger delivery pipeRadiator drain cockFront spoiler shieldUpper oxygen sensor (threads coated lightly with thread paste); torque sensor to 30 ft. lbs. (40 Nm)Oxygen sensor and temperature sensor connectorsVacuum unit to turbochargerControl rod to control armPipe for crankcase ventilation (B205R)Control valve hoses to turbochargerTurbocharger heat shield

    Catalytic converter heat shield
     
    Steering gear heat shield
     
    Catalytic converter and pipe to front muffler; torque joint of converter to 19 ft. lbs. (25 Nm) and joint clamp nuts to 30 ft. lbs. (40 Nm)
     
    Turbocharger delivery pipe
     
    Radiator drain cock
     
    Front spoiler shield
     
    Upper oxygen sensor (threads coated lightly with thread paste); torque sensor to 30 ft. lbs. (40 Nm)
     
    Oxygen sensor and temperature sensor connectors
     
    Vacuum unit to turbocharger
     
    Control rod to control arm
     
    Pipe for crankcase ventilation (B205R)
     
    Control valve hoses to turbocharger
     
    Turbocharger heat shield
     

  18.  


WARNING
To reduce the risk that turbocharger hoses will come loose under pressure, thoroughly clean all fittings and inside of hoses before connecting.



Air cleaner housing and turbocharger inlet hose
 
Crankcase vent hose to camshaft cover and turbocharger and hose from solenoid valve
 
Negative battery cable
 

  1. Fill cooling system and bleed by starting engine (A/C off) and running at varying speeds until the cooling fan comes on. Turn engine off and top up coolant in expansion tank.
  2.  
  3. Check for leaks.
  4.  

2003-06 Models (Except 2.8L Engine)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove expansion tank cap to release any pressure.
  4.  
  5. Remove or disconnect the following:

    Upper oxygen sensor and temperature sensor connectors
     
    Crankcase vent hose from camshaft cover and turbocharger inlet (B207L)
     
    Air cleaner housing and turbo inlet hose
     
    Hose to crankcase ventilation and secondary air injection (SAI) hose (B205R)
     
    Turbocharger heat shield
     
    Solenoid valve hoses from turbocharger (B205R)
     
    Pipe connection for crankcase ventilation (B205R)
     
    Locking clip from turbocharger control arm
     
    Vacuum unit from turbocharger
     
    Hose from turbocharger bypass (B205R)
     
    Upper oxygen sensor
     
    Catalytic converter connection from turbocharger
     
    Front spoiler shield
     
    Drain the cooling system (radiator and water pump)
     
    Coolant pipe from turbocharger and cylinder head (grip inner connection so it does not come off turbo)
     
    Oil pipe from turbocharger
     
    Lower pressure pipe from turbocharger
     
    Front exhaust pipe from catalytic converter
     
    Steering gear heat shield
     
    Catalytic converter heat shield
     
    Temperature sensor
     
    Lower oxygen sensor
     
    Catalytic converter retainer from engine block
     
    Catalytic converter
     
    Coolant pipe from turbocharger and thermostat housing
     
    Oil return pipe from turbocharger and engine block (collect O-ring)
     
    Stay between engine block and turbocharger (B205R)
     
    Oil pressure pipe from engine block
     
    Turbocharger from bottom of car
     

  6.  

To install:

  1. Install a new gasket for turbocharger.
  2.  
  3. Coat turbocharger stud bolts and exhaust manifold stud bolts with thread paste.
  4.  
  5. Raise and position turbocharger to engine. Tighten mounting stud bolts to 18 ft. lbs. (24 Nm).
  6.  
  7. Install or connect the following:

    Oil return pipe to turbocharger, with new gasket and O-ring; torque to 11 ft. lbs. (15 Nm).
     
    Coolant pipe between turbocharger and thermostat housing, with new sealing washers; torque to 15 ft. lbs. (20 Nm)
     
    Bolt, with new sealing washers, for turbocharger oil delivery pipe on engine block; do not tighten
     
    Stay between turbocharger and engine block torqued to 24 ft. lbs. (32 Nm) for bolt in turbocharger and 35 ft. lbs. (48 Nm) for M10 bolt
     
    Fill turbocharger oil delivery connection with clean engine oil while turning turbine wheel
     
    Oil delivery pipe to turbocharger and tighten connection, with new sealing washers; torque to 21 ft. lbs. (28 Nm)
     
    Coolant pipe to turbocharger and pipe mounting on cylinder head
     
    Hose to bypass valve
     
    Oil delivery pipe connection on engine block (from under car); torque to 21 ft. lbs. (28 Nm)
     

  8.  
  9. Position the catalytic converter with new nuts on studs to 7 ft. lbs. (10 Nm). Ensure converter rests against turbocharger.
  10.  
  11. Raise the car and tighten the catalytic converter nuts to 18 ft. lbs. (25 Nm) and bolts to 16 ft. lbs. (22 Nm) a last time.
  12.  
  13. Lightly coat threads of lower oxygen sensor with thread paste and install sensor. Torque it to 30 ft. lbs. (40 Nm). Be sure oxygen sensor cables are not twisted or damaged.
  14.  
  15. Lightly coat threads of temperature sensor with thread paste and install sensor. Tighten to 33 ft. lbs. (45 Nm). Check to be sure all wiring from oxygen sensor and temperature sensor is not twisted or damaged.
  16.  
  17. Install or connect the following:
    WARNING
    To reduce the risk that turbocharger hoses will come loose under pressure, thoroughly clean all fittings and inside of hoses before connecting.



    Catalytic converter heat shield
     
    Steering gear heat shield
     
    Catalytic converter and pipe to front muffler; torque joint of converter to 19 ft. lbs. (25 Nm) and joint clamp nuts to 30 ft. lbs. (40 Nm)
     
    Turbocharger delivery pipe
     
    Radiator drain cock
     
    Front spoiler shield
     
    Upper oxygen sensor (threads coated lightly with thread paste); torque sensor to 30 ft. lbs. (40 Nm)
     
    Oxygen sensor and temperature sensor connectors
     
    Vacuum unit to turbocharger
     
    Control rod to control arm
     
    Pipe for crankcase ventilation (B205R)
     
    Control valve hoses to turbocharger
     
    Turbocharger heat shield
     



    Air cleaner housing and turbocharger inlet hose
     
    Crankcase vent hose to camshaft cover and turbocharger and hose from solenoid valve
     
    Negative battery cable
     

  18.  
  19. Fill cooling system and bleed by starting engine (A/C off) and running at varying speeds until the cooling fan comes on. Turn engine off and top up coolant in expansion tank.
  20.  
  21. Check for leaks.
  22.  

9-5
2.3L Engine
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove lower front cover and drain the cooling system.
  4.  
  5. Remove or disconnect the following: Negative battery cableTurbocharger staysLoosen the oil return pipe from the turbocharger to the engineOil pipe between the oil filter adapter and the turbochargerBypass pipe and valveControl valve connectorMass Air Flow (MAF) sensor electrical connectorLoosen hoses to turbocharger and diaphragm housingCrankcase breather pipeEngine lifting eyeMAF sensor and air hoseExhaust manifold heat shieldQuick-release coupling on the vent hoseIntake manifold V-clampIntake manifoldHose between the turbocharger and the charge air coolerExhaust system from the turbochargerOil pipe from the oil filter adapter and copper washersCoolant pipe to the turbochargerCoolant return pipe from the cylinder head and the pressure sensor bracketTurbocharger

    Negative battery cable
     
    Turbocharger stays
     
    Loosen the oil return pipe from the turbocharger to the engine
     
    Oil pipe between the oil filter adapter and the turbocharger
     
    Bypass pipe and valve
     
    Control valve connector
     
    Mass Air Flow (MAF) sensor electrical connector
     
    Loosen hoses to turbocharger and diaphragm housing
     
    Crankcase breather pipe
     
    Engine lifting eye
     
    MAF sensor and air hose
     
    Exhaust manifold heat shield
     
    Quick-release coupling on the vent hose
     
    Intake manifold V-clamp
     
    Intake manifold
     
    Hose between the turbocharger and the charge air cooler
     
    Exhaust system from the turbocharger
     
    Oil pipe from the oil filter adapter and copper washers
     
    Coolant pipe to the turbocharger
     
    Coolant return pipe from the cylinder head and the pressure sensor bracket
     
    Turbocharger
     

  6.  

To install:

  1. Install or connect the following: Turbocharger and torque the 2 upper bolts to 18 ft. lbs. (24 Nm)Coolant return pipe with new copper washers and torque the nipple to 26 ft. lbs. (35 Nm), the banjo bolt to 19 ft. lbs. (25 Nm), the coolant return pipe to 19 ft. lbs. (25 Nm) and the coolant return pipe clamp to 7 ft. lbs. (9 Nm)Turbocharger oil pipe with new copper washers and torque the banjo bolt to 15 ft. lbs. (20 Nm)Turbocharger intake pipe with a new O-ring and loosen the adjusting screw on the intake manifoldTorque the V clamp between the turbocharger to intake pipe to 2.5 ft. lbs. (4 Nm) and the intake manifold and adjusting screw to 18 ft. lbs. (24 Nm).Hoses to the turbocharger and diaphragm housingCharge air cooler inlet hose and torque the bolts to 6 ft. lbs. (8 Nm)Heat shield and torque the bolts to 15 ft. lbs. (20 Nm)MAF sensor and air hoseEngine lifting eyeCrankcase breather pipe and torque the bolts to 18 ft. lbs. (24 Nm)Charge air bypass valve and pipe with a new O-ring and torque the bolts to 6 ft. lbs. (8 Nm)Lower nut to the turbo charger and torque the stud to 16 ft. lbs. (22 Nm) and the lock nut to 18 ft. lbs. (24 Nm)Turbocharger oil pipe with new copper washers and torque the bolt to 19 ft. lbs. (25 Nm)Turbocharger stays and torque to 18 ft. lbs. (24 Nm)Oil return pipe between the turbocharger and engine and torque the bolts to 10 ft. lbs. (15 Nm)Lower engine coverNegative battery cable

    Turbocharger and torque the 2 upper bolts to 18 ft. lbs. (24 Nm)
     
    Coolant return pipe with new copper washers and torque the nipple to 26 ft. lbs. (35 Nm), the banjo bolt to 19 ft. lbs. (25 Nm), the coolant return pipe to 19 ft. lbs. (25 Nm) and the coolant return pipe clamp to 7 ft. lbs. (9 Nm)
     
    Turbocharger oil pipe with new copper washers and torque the banjo bolt to 15 ft. lbs. (20 Nm)
     
    Turbocharger intake pipe with a new O-ring and loosen the adjusting screw on the intake manifold
     
    Torque the V clamp between the turbocharger to intake pipe to 2.5 ft. lbs. (4 Nm) and the intake manifold and adjusting screw to 18 ft. lbs. (24 Nm).
     
    Hoses to the turbocharger and diaphragm housing
     
    Charge air cooler inlet hose and torque the bolts to 6 ft. lbs. (8 Nm)
     
    Heat shield and torque the bolts to 15 ft. lbs. (20 Nm)
     
    MAF sensor and air hose
     
    Engine lifting eye
     
    Crankcase breather pipe and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Charge air bypass valve and pipe with a new O-ring and torque the bolts to 6 ft. lbs. (8 Nm)
     
    Lower nut to the turbo charger and torque the stud to 16 ft. lbs. (22 Nm) and the lock nut to 18 ft. lbs. (24 Nm)
     
    Turbocharger oil pipe with new copper washers and torque the bolt to 19 ft. lbs. (25 Nm)
     
    Turbocharger stays and torque to 18 ft. lbs. (24 Nm)
     
    Oil return pipe between the turbocharger and engine and torque the bolts to 10 ft. lbs. (15 Nm)
     
    Lower engine cover
     
    Negative battery cable
     

  2.  
  3. Fill the engine with coolant.
  4.  
  5. Start the vehicle and run at varying speeds until radiator fan comes on. Stop the engine and top up the coolant and engine oil as needed.
  6.  
  7. Check for leaks and repair if necessary.
  8.  

  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove lower front cover and drain the cooling system.
  4.  
  5. Remove or disconnect the following: Negative battery cableTurbocharger staysLoosen the oil return pipe from the turbocharger to the engineOil pipe between the oil filter adapter and the turbochargerBypass pipe and valveControl valve connectorMass Air Flow (MAF) sensor electrical connectorLoosen hoses to turbocharger and diaphragm housingCrankcase breather pipeEngine lifting eyeMAF sensor and air hoseExhaust manifold heat shieldQuick-release coupling on the vent hoseIntake manifold V-clampIntake manifoldHose between the turbocharger and the charge air coolerExhaust system from the turbochargerOil pipe from the oil filter adapter and copper washersCoolant pipe to the turbochargerCoolant return pipe from the cylinder head and the pressure sensor bracketTurbocharger

    Negative battery cable
     
    Turbocharger stays
     
    Loosen the oil return pipe from the turbocharger to the engine
     
    Oil pipe between the oil filter adapter and the turbocharger
     
    Bypass pipe and valve
     
    Control valve connector
     
    Mass Air Flow (MAF) sensor electrical connector
     
    Loosen hoses to turbocharger and diaphragm housing
     
    Crankcase breather pipe
     
    Engine lifting eye
     
    MAF sensor and air hose
     
    Exhaust manifold heat shield
     
    Quick-release coupling on the vent hose
     
    Intake manifold V-clamp
     
    Intake manifold
     
    Hose between the turbocharger and the charge air cooler
     
    Exhaust system from the turbocharger
     
    Oil pipe from the oil filter adapter and copper washers
     
    Coolant pipe to the turbocharger
     
    Coolant return pipe from the cylinder head and the pressure sensor bracket
     
    Turbocharger
     

  6.  

To install:

  1. Install or connect the following: Turbocharger and torque the 2 upper bolts to 18 ft. lbs. (24 Nm)Coolant return pipe with new copper washers and torque the nipple to 26 ft. lbs. (35 Nm), the banjo bolt to 19 ft. lbs. (25 Nm), the coolant return pipe to 19 ft. lbs. (25 Nm) and the coolant return pipe clamp to 7 ft. lbs. (9 Nm)Turbocharger oil pipe with new copper washers and torque the banjo bolt to 15 ft. lbs. (20 Nm)Turbocharger intake pipe with a new O-ring and loosen the adjusting screw on the intake manifoldTorque the V clamp between the turbocharger to intake pipe to 30 inch lbs. (4 Nm) and the intake manifold and adjusting screw to 18 ft. lbs. (24 Nm).Hoses to the turbocharger and diaphragm housingCharge air cooler inlet hose and torque the bolts to 72 inch lbs. (8 Nm)Heat shield and torque the bolts to 15 ft. lbs. (20 Nm)MAF sensor and air hoseEngine lifting eyeCrankcase breather pipe and torque the bolts to 18 ft. lbs. (24 Nm)Charge air bypass valve and pipe with a new O-ring and torque the bolts to 6 ft. lbs. (8 Nm)Lower nut to the turbo charger and torque the stud to 16 ft. lbs. (22 Nm) and the lock nut to 18 ft. lbs. (24 Nm)Turbocharger oil pipe with new copper washers and torque the bolt to 19 ft. lbs. (25 Nm)Turbocharger stays and torque to 18 ft. lbs. (24 Nm)Oil return pipe between the turbocharger and engine and torque the bolts to 10 ft. lbs. (15 Nm)Lower engine coverNegative battery cable

    Turbocharger and torque the 2 upper bolts to 18 ft. lbs. (24 Nm)
     
    Coolant return pipe with new copper washers and torque the nipple to 26 ft. lbs. (35 Nm), the banjo bolt to 19 ft. lbs. (25 Nm), the coolant return pipe to 19 ft. lbs. (25 Nm) and the coolant return pipe clamp to 7 ft. lbs. (9 Nm)
     
    Turbocharger oil pipe with new copper washers and torque the banjo bolt to 15 ft. lbs. (20 Nm)
     
    Turbocharger intake pipe with a new O-ring and loosen the adjusting screw on the intake manifold
     
    Torque the V clamp between the turbocharger to intake pipe to 30 inch lbs. (4 Nm) and the intake manifold and adjusting screw to 18 ft. lbs. (24 Nm).
     
    Hoses to the turbocharger and diaphragm housing
     
    Charge air cooler inlet hose and torque the bolts to 72 inch lbs. (8 Nm)
     
    Heat shield and torque the bolts to 15 ft. lbs. (20 Nm)
     
    MAF sensor and air hose
     
    Engine lifting eye
     
    Crankcase breather pipe and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Charge air bypass valve and pipe with a new O-ring and torque the bolts to 6 ft. lbs. (8 Nm)
     
    Lower nut to the turbo charger and torque the stud to 16 ft. lbs. (22 Nm) and the lock nut to 18 ft. lbs. (24 Nm)
     
    Turbocharger oil pipe with new copper washers and torque the bolt to 19 ft. lbs. (25 Nm)
     
    Turbocharger stays and torque to 18 ft. lbs. (24 Nm)
     
    Oil return pipe between the turbocharger and engine and torque the bolts to 10 ft. lbs. (15 Nm)
     
    Lower engine cover
     
    Negative battery cable
     

  2.  
  3. Fill the engine with coolant.
  4.  
  5. Start the vehicle and run at varying speeds until radiator fan comes on. Stop the engine and top up the coolant and engine oil as needed.
  6.  
  7. Check for leaks and repair if necessary.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove lower front cover and drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Turbocharger stays
     
    Loosen the oil return pipe from the turbocharger to the engine
     
    Oil pipe between the oil filter adapter and the turbocharger
     
    Bypass pipe and valve
     
    Control valve connector
     
    Mass Air Flow (MAF) sensor electrical connector
     
    Loosen hoses to turbocharger and diaphragm housing
     
    Crankcase breather pipe
     
    Engine lifting eye
     
    MAF sensor and air hose
     
    Exhaust manifold heat shield
     
    Quick-release coupling on the vent hose
     
    Intake manifold V-clamp
     
    Intake manifold
     
    Hose between the turbocharger and the charge air cooler
     
    Exhaust system from the turbocharger
     
    Oil pipe from the oil filter adapter and copper washers
     
    Coolant pipe to the turbocharger
     
    Coolant return pipe from the cylinder head and the pressure sensor bracket
     
    Turbocharger
     

  6.  

To install:

  1. Install or connect the following:

    Turbocharger and torque the 2 upper bolts to 18 ft. lbs. (24 Nm)
     
    Coolant return pipe with new copper washers and torque the nipple to 26 ft. lbs. (35 Nm), the banjo bolt to 19 ft. lbs. (25 Nm), the coolant return pipe to 19 ft. lbs. (25 Nm) and the coolant return pipe clamp to 7 ft. lbs. (9 Nm)
     
    Turbocharger oil pipe with new copper washers and torque the banjo bolt to 15 ft. lbs. (20 Nm)
     
    Turbocharger intake pipe with a new O-ring and loosen the adjusting screw on the intake manifold
     
    Torque the V clamp between the turbocharger to intake pipe to 30 inch lbs. (4 Nm) and the intake manifold and adjusting screw to 18 ft. lbs. (24 Nm).
     
    Hoses to the turbocharger and diaphragm housing
     
    Charge air cooler inlet hose and torque the bolts to 72 inch lbs. (8 Nm)
     
    Heat shield and torque the bolts to 15 ft. lbs. (20 Nm)
     
    MAF sensor and air hose
     
    Engine lifting eye
     
    Crankcase breather pipe and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Charge air bypass valve and pipe with a new O-ring and torque the bolts to 6 ft. lbs. (8 Nm)
     
    Lower nut to the turbo charger and torque the stud to 16 ft. lbs. (22 Nm) and the lock nut to 18 ft. lbs. (24 Nm)
     
    Turbocharger oil pipe with new copper washers and torque the bolt to 19 ft. lbs. (25 Nm)
     
    Turbocharger stays and torque to 18 ft. lbs. (24 Nm)
     
    Oil return pipe between the turbocharger and engine and torque the bolts to 10 ft. lbs. (15 Nm)
     
    Lower engine cover
     
    Negative battery cable
     

  2.  
  3. Fill the engine with coolant.
  4.  
  5. Start the vehicle and run at varying speeds until radiator fan comes on. Stop the engine and top up the coolant and engine oil as needed.
  6.  
  7. Check for leaks and repair if necessary.
  8.  

3.0L Engine
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove the upper engine cover.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following: Negative battery cableTurbocharger pressure hose with the bypass pipe and valve (plug opening)Exhaust manifold heat shieldCrankcase breather pipe (bend pipe aside)Turbocharger intake pipe (bend pipe aside)Turbocharger outlet hose to the charge air coolerRadiator fan and clamp off the coolant hoses to the turbochargerCoolant pipesDipstick tubeFront pipe from the turbochargerOxygen sensor connectorSeparate front and rear exhaust systemsFront pipe from the rear exhaust manifoldTurbocharger oil return pipeTurbocharger mounting bracketOil pipe from oil filter adapterFront exhaust manifold and turbocharger as an assembly

    Negative battery cable
     
    Turbocharger pressure hose with the bypass pipe and valve (plug opening)
     
    Exhaust manifold heat shield
     
    Crankcase breather pipe (bend pipe aside)
     
    Turbocharger intake pipe (bend pipe aside)
     
    Turbocharger outlet hose to the charge air cooler
     
    Radiator fan and clamp off the coolant hoses to the turbocharger
     
    Coolant pipes
     
    Dipstick tube
     
    Front pipe from the turbocharger
     
    Oxygen sensor connector
     
    Separate front and rear exhaust systems
     
    Front pipe from the rear exhaust manifold
     
    Turbocharger oil return pipe
     
    Turbocharger mounting bracket
     
    Oil pipe from oil filter adapter
     
    Front exhaust manifold and turbocharger as an assembly
     

  8.  


    Click image to see an enlarged view

    Fig. Remove the turbocharger and exhaust manifold as an assembly


To install:

  1. Fill the turbo inlet with oil. Rotate the compressor wheel by hand several times to assure the bearings are well lubricated.
  2.  
  3. Install or connect the following: Turbocharger and exhaust manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)Front pipe to the exhaust manifold with a new gasket and torque the bolts to 30 ft. lbs. (40 Nm)Pipe joint between the front and rear exhaust systems and torque the bolts to 16 ft. lbs. (22 Nm)Oxygen sensor wiring harness (secure with cable tie)Oil pipe to the oil filter adapter with new gaskets and sealing washers and torque the bolts to 15 ft. lbs. (20 Nm)Turbocharger mounting bracket and torque the bolts to 18 ft. lbs. (24 Nm)Oil return pipe and torque the bolts to 10 ft. lbs. (15 Nm)Oxygen sensor connectorFront exhaust pipe to the turbocharger and torque the bolts to 18 ft. lbs. (24 Nm)Dipstick tubeCoolant pipes with new sealing washers and torque the banjo bolt to 19 ft. lbs. (25 Nm) and the cylinder head retaining screw to 10 ft. lbs. (15 Nm)Radiator fan and unclamp the coolant hosesHose between the turbocharger and charge air cooler and torque the fasteners to 6 ft. lbs. (8 Nm)Turbocharger intake pipe and torque V-clamp to 2 ft. lbs. (3 Nm) and U-clamp to 10 ft. lbs. (15 Nm)Crankcase breather pipe and torque the banjo bolt to 18 ft. lbs. (24 Nm)Exhaust manifold heat shield and torque stud to 16 ft. lbs. (22 Nm) and lock nut to 18 ft. lbs. (24 Nm)Turbocharger pressure hose with the bypass pipe and valve and torque to 6 ft. lbs. (8 Nm)Negative battery cableEngine upper cover

    Turbocharger and exhaust manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Front pipe to the exhaust manifold with a new gasket and torque the bolts to 30 ft. lbs. (40 Nm)
     
    Pipe joint between the front and rear exhaust systems and torque the bolts to 16 ft. lbs. (22 Nm)
     
    Oxygen sensor wiring harness (secure with cable tie)
     
    Oil pipe to the oil filter adapter with new gaskets and sealing washers and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Turbocharger mounting bracket and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Oil return pipe and torque the bolts to 10 ft. lbs. (15 Nm)
     
    Oxygen sensor connector
     
    Front exhaust pipe to the turbocharger and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Dipstick tube
     
    Coolant pipes with new sealing washers and torque the banjo bolt to 19 ft. lbs. (25 Nm) and the cylinder head retaining screw to 10 ft. lbs. (15 Nm)
     
    Radiator fan and unclamp the coolant hoses
     
    Hose between the turbocharger and charge air cooler and torque the fasteners to 6 ft. lbs. (8 Nm)
     
    Turbocharger intake pipe and torque V-clamp to 2 ft. lbs. (3 Nm) and U-clamp to 10 ft. lbs. (15 Nm)
     
    Crankcase breather pipe and torque the banjo bolt to 18 ft. lbs. (24 Nm)
     
    Exhaust manifold heat shield and torque stud to 16 ft. lbs. (22 Nm) and lock nut to 18 ft. lbs. (24 Nm)
     
    Turbocharger pressure hose with the bypass pipe and valve and torque to 6 ft. lbs. (8 Nm)
     
    Negative battery cable
     
    Engine upper cover
     

  4.  
  5. Fill the cooling system to the proper level.
  6.  
  7. Start the vehicle, check for leaks and repair if necessary.
  8.  

  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove the upper engine cover.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following: Negative battery cableTurbocharger pressure hose with the bypass pipe and valve (plug opening)Exhaust manifold heat shieldCrankcase breather pipe (bend pipe aside)Turbocharger intake pipe (bend pipe aside)Turbocharger outlet hose to the charge air coolerRadiator fan and clamp off the coolant hoses to the turbochargerCoolant pipesDipstick tubeFront pipe from the turbochargerOxygen sensor connectorSeparate front and rear exhaust systemsFront pipe from the rear exhaust manifoldTurbocharger oil return pipeTurbocharger mounting bracketOil pipe from oil filter adapterFront exhaust manifold and turbocharger as an assembly

    Negative battery cable
     
    Turbocharger pressure hose with the bypass pipe and valve (plug opening)
     
    Exhaust manifold heat shield
     
    Crankcase breather pipe (bend pipe aside)
     
    Turbocharger intake pipe (bend pipe aside)
     
    Turbocharger outlet hose to the charge air cooler
     
    Radiator fan and clamp off the coolant hoses to the turbocharger
     
    Coolant pipes
     
    Dipstick tube
     
    Front pipe from the turbocharger
     
    Oxygen sensor connector
     
    Separate front and rear exhaust systems
     
    Front pipe from the rear exhaust manifold
     
    Turbocharger oil return pipe
     
    Turbocharger mounting bracket
     
    Oil pipe from oil filter adapter
     
    Front exhaust manifold and turbocharger as an assembly
     

  8.  


    Click image to see an enlarged view

    Fig. Remove the turbocharger and exhaust manifold as an assembly


To install:

  1. Fill the turbo inlet with oil. Rotate the compressor wheel by hand several times to assure the bearings are well lubricated.
  2.  
  3. Install or connect the following: Turbocharger and exhaust manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)Front pipe to the exhaust manifold with a new gasket and torque the bolts to 30 ft. lbs. (40 Nm)Pipe joint between the front and rear exhaust systems and torque the bolts to 16 ft. lbs. (22 Nm)Oxygen sensor wiring harness (secure with cable tie)Oil pipe to the oil filter adapter with new gaskets and sealing washers and torque the bolts to 15 ft. lbs. (20 Nm)Turbocharger mounting bracket and torque the bolts to 18 ft. lbs. (24 Nm)Oil return pipe and torque the bolts to 10 ft. lbs. (15 Nm)Oxygen sensor connectorFront exhaust pipe to the turbocharger and torque the bolts to 18 ft. lbs. (24 Nm)Dipstick tubeCoolant pipes with new sealing washers and torque the banjo bolt to 19 ft. lbs. (25 Nm) and the cylinder head retaining screw to 10 ft. lbs. (15 Nm)Radiator fan and unclamp the coolant hosesHose between the turbocharger and charge air cooler and torque the fasteners to 72 inch lbs. (8 Nm)Turbocharger intake pipe and torque V-clamp to 24 inch lbs. (3 Nm) and U-clamp to 10 ft. lbs. (15 Nm)Crankcase breather pipe and torque the banjo bolt to 18 ft. lbs. (24 Nm)Exhaust manifold heat shield and torque stud to 16 ft. lbs. (22 Nm) and lock nut to 18 ft. lbs. (24 Nm)Turbocharger pressure hose with the bypass pipe and valve and torque to 72 inch lbs. (8 Nm)Negative battery cableEngine upper cover

    Turbocharger and exhaust manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Front pipe to the exhaust manifold with a new gasket and torque the bolts to 30 ft. lbs. (40 Nm)
     
    Pipe joint between the front and rear exhaust systems and torque the bolts to 16 ft. lbs. (22 Nm)
     
    Oxygen sensor wiring harness (secure with cable tie)
     
    Oil pipe to the oil filter adapter with new gaskets and sealing washers and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Turbocharger mounting bracket and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Oil return pipe and torque the bolts to 10 ft. lbs. (15 Nm)
     
    Oxygen sensor connector
     
    Front exhaust pipe to the turbocharger and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Dipstick tube
     
    Coolant pipes with new sealing washers and torque the banjo bolt to 19 ft. lbs. (25 Nm) and the cylinder head retaining screw to 10 ft. lbs. (15 Nm)
     
    Radiator fan and unclamp the coolant hoses
     
    Hose between the turbocharger and charge air cooler and torque the fasteners to 72 inch lbs. (8 Nm)
     
    Turbocharger intake pipe and torque V-clamp to 24 inch lbs. (3 Nm) and U-clamp to 10 ft. lbs. (15 Nm)
     
    Crankcase breather pipe and torque the banjo bolt to 18 ft. lbs. (24 Nm)
     
    Exhaust manifold heat shield and torque stud to 16 ft. lbs. (22 Nm) and lock nut to 18 ft. lbs. (24 Nm)
     
    Turbocharger pressure hose with the bypass pipe and valve and torque to 72 inch lbs. (8 Nm)
     
    Negative battery cable
     
    Engine upper cover
     

  4.  
  5. Fill the cooling system to the proper level.
  6.  
  7. Start the vehicle, check for leaks and repair if necessary.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the upper engine cover.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Turbocharger pressure hose with the bypass pipe and valve (plug opening)
     
    Exhaust manifold heat shield
     
    Crankcase breather pipe (bend pipe aside)
     
    Turbocharger intake pipe (bend pipe aside)
     
    Turbocharger outlet hose to the charge air cooler
     
    Radiator fan and clamp off the coolant hoses to the turbocharger
     
    Coolant pipes
     
    Dipstick tube
     
    Front pipe from the turbocharger
     
    Oxygen sensor connector
     
    Separate front and rear exhaust systems
     
    Front pipe from the rear exhaust manifold
     
    Turbocharger oil return pipe
     
    Turbocharger mounting bracket
     
    Oil pipe from oil filter adapter
     
    Front exhaust manifold and turbocharger as an assembly

    Click image to see an enlarged view

    Fig. Remove the turbocharger and exhaust manifold as an assembly

     

  8.  

To install:

  1. Fill the turbo inlet with oil. Rotate the compressor wheel by hand several times to assure the bearings are well lubricated.
  2.  
  3. Install or connect the following:

    Turbocharger and exhaust manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Front pipe to the exhaust manifold with a new gasket and torque the bolts to 30 ft. lbs. (40 Nm)
     
    Pipe joint between the front and rear exhaust systems and torque the bolts to 16 ft. lbs. (22 Nm)
     
    Oxygen sensor wiring harness (secure with cable tie)
     
    Oil pipe to the oil filter adapter with new gaskets and sealing washers and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Turbocharger mounting bracket and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Oil return pipe and torque the bolts to 10 ft. lbs. (15 Nm)
     
    Oxygen sensor connector
     
    Front exhaust pipe to the turbocharger and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Dipstick tube
     
    Coolant pipes with new sealing washers and torque the banjo bolt to 19 ft. lbs. (25 Nm) and the cylinder head retaining screw to 10 ft. lbs. (15 Nm)
     
    Radiator fan and unclamp the coolant hoses
     
    Hose between the turbocharger and charge air cooler and torque the fasteners to 72 inch lbs. (8 Nm)
     
    Turbocharger intake pipe and torque V-clamp to 24 inch lbs. (3 Nm) and U-clamp to 10 ft. lbs. (15 Nm)
     
    Crankcase breather pipe and torque the banjo bolt to 18 ft. lbs. (24 Nm)
     
    Exhaust manifold heat shield and torque stud to 16 ft. lbs. (22 Nm) and lock nut to 18 ft. lbs. (24 Nm)
     
    Turbocharger pressure hose with the bypass pipe and valve and torque to 72 inch lbs. (8 Nm)
     
    Negative battery cable
     
    Engine upper cover
     

  4.  
  5. Fill the cooling system to the proper level.
  6.  
  7. Start the vehicle, check for leaks and repair if necessary.
  8.  

 
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