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Turbocharger replacement

Turbocharger replacement


Special Tools

EN-50098 Stretchy Belt Installer

For equivalent regional tools, refer to Special Tools .

Removal Procedure


1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

2. Disconnect the electrical connector of the Heated Oxygen Sensor - Sensor 1. Refer to Heated Oxygen Sensor Replacement - Sensor 1 (LLU/A16LET) .

3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

4.
Note

After draining the engine oil, install the drain plug with a new O-ring seal.


Remove the drain plug and drain engine oil. Refer to Engine Oil and Oil Filter Replacement (LLU/A16LET) .

5. Remove the charge air cooler inlet air hose. Refer to Charge Air Cooler Inlet Hose Replacement (LAU/A28NER) Charge Air Cooler Inlet Hose Replacement (LBY/A20DTR) Charge Air Cooler Inlet Hose Replacement (LLU/A16LET) Charge Air Cooler Inlet Hose Replacement (LBS/A20DTH) .

6. Remove turbocharger oil return hose. Refer to Turbocharger Oil Return Hose Replacement .

7. Remove exhaust front pipe. Refer to Exhaust Front Pipe Replacement (LBY/A20DTR) Exhaust Front Pipe Replacement (LLU/A16LET) Exhaust Front Pipe Replacement (LBS/A20DTH) Exhaust Front Pipe Replacement (LHU/A20NFT, LAU/A28NER) .

8. Remove the catalytic converter. Refer to Catalytic Converter Replacement (LAU/A28NER) Catalytic Converter Replacement (LBY/A20DTR) Catalytic Converter Replacement (LLU/A16LET) Catalytic Converter Replacement (LBS/A20DTH) Catalytic Converter Replacement (LHU/A20NFT) Catalytic Converter Replacement (LHU/A20NFT - AWD) .

9. Lower the vehicle.

10. Open the coolant drain plug. Refer to Cooling System Draining and Filling (LAU/A28NER) Cooling System Draining and Filling (LBS/A20DTH) Cooling System Draining and Filling (LHU/A20NFT) .

11. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (LLU/A16LET) .

12. Remove the stretch drive belt (1) from the power steering pump (2).


13.
Note

Secure power steering pump with a cable tie.


Remove the 3 fasteners (3) of the power steering pump.

14. Remove the turbocharger wastegate regulator solenoid valve. Refer to Turbocharger Wastegate Regulator Solenoid Valve Replacement (LLU/A16LET) .

15. Remove the turbocharger air inlet adapter. Refer to Turbocharger Air Inlet Adapter Replacement (LLU/A16LET) .

16. Remove the fastener (1) of the oil level indicator tube.


17. Remove the 2 fastener of the exhaust manifold heat shield.

18. Remove the vacuum hose from the turbocharger.

19. Remove turbocharger coolant return hose from turbocharger coolant return pipe.

20. Remove turbocharger coolant feed pipe from turbocharger. Refer to Turbocharger Coolant Feed Pipe Replacement (LAU/A28NER) Turbocharger Coolant Feed Pipe Replacement (LLU/A16LET) Turbocharger Coolant Feed Pipe Replacement (LHU/A20NFT) .

21.
Note

After removing the exhaust manifold assembly, turn the turbocharger oil feed pipe 90 degrees to release the retainer (3).


Remove the turbocharger oil feed pipe (2) from the turbocharger.


22. Remove the turbocharger oil feed pipe hollow bolt (1) and the 2 sealing rings (4).

23. Remove the nine turbocharger fasteners (1).


24. Remove the turbocharger fasteners (3).

25. Remove the exhaust manifold gasket (2).

26. Remove the hollow bolt and the fastener of the coolant return pipe from the exhaust manifold assembly.


Installation Procedure


1. Clean the exhaust manifold gasket surface.

2. Install a new exhaust manifold gasket (2) to the exhaust manifold.


3. Install the hollow bolt with new seal rings and the fastener of the coolant return pipe to the exhaust manifold assembly.

4.
Note

Put the turbocharger oil feed pipe into the terminal and turn the pipe 90 degrees.


Install the turbocharger oil feed pipe with a new seal ring.

5. Install the turbocharger (3).

6. Refer to Fastener Caution .

Install 9 new turbocharger fasteners (1) and tighten to 8 Nm (71 lb in) .

7. Install the turbocharger oil feed pipe (2) to the turbocharger.


8. Install the turbocharger oil feed pipe hollow bolt (1) and 2 new sealing rings (4) and tighten to 30 Nm (22 lb ft) .

9. Install the turbocharger coolant feed pipe to the turbocharger. Refer to Turbocharger Coolant Feed Pipe Replacement (LAU/A28NER) Turbocharger Coolant Feed Pipe Replacement (LLU/A16LET) Turbocharger Coolant Feed Pipe Replacement (LHU/A20NFT) .

10. Install the turbocharger coolant return hose to the turbocharger coolant return pipe.

11.
Note

Install the 2 fastener hand-screwed.


Install the 2 fastener of the exhaust manifold heat shield.

12. Install the oil level indicator tube with 2 new seal rings.


13. Install the oil level indicator tube fastener (1) and tighten to 8 Nm (71 lb in) .

14. Attach the exhaust manifold heat shield and tighten to 8 Nm (71 lb in) .

15. Install the turbocharger wastegate regulator solenoid valve to the turbocharger air inlet adapter. Refer to Turbocharger Wastegate Regulator Solenoid Valve Replacement (LLU/A16LET) .

16. Install the turbocharger air inlet adapter. Refer to Turbocharger Air Inlet Adapter Replacement (LLU/A16LET)

17. Install the vacuum hose to the turbocharger.

18. Install the power steering pump (2).


19. Install the 3 fasteners (3) for the power steering pump and tighten to 22 Nm (16 lb ft) .

20. Install the stretch drive belt (1) to the power steering pump.

21.
Note

During turning the engine, take care of the proper installation of the belt to belt pulley water pump.


Mount EN-50098 stretchy belt installer (1) and stretch drive belt (2) to power steering pump belt pulley (3) and turn engine slowly clockwise.


22. Remove EN-50098 stretchy belt installer.

23. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (LLU/A16LET) .

24. Connect the electrical connector to the turbocharger wastegate regulator solenoid valve.

25. Raise the vehicle.

26. Install the turbocharger oil return hose. Refer to Turbocharger Oil Return Hose Replacement .

27. Install the charge air cooler inlet air hose. Refer to Charge Air Cooler Inlet Hose Replacement (LAU/A28NER) Charge Air Cooler Inlet Hose Replacement (LBY/A20DTR) Charge Air Cooler Inlet Hose Replacement (LLU/A16LET) Charge Air Cooler Inlet Hose Replacement (LBS/A20DTH) .

28. Install the catalytic converter. Refer to Catalytic Converter Replacement (LAU/A28NER) Catalytic Converter Replacement (LBY/A20DTR) Catalytic Converter Replacement (LLU/A16LET) Catalytic Converter Replacement (LBS/A20DTH) Catalytic Converter Replacement (LHU/A20NFT) Catalytic Converter Replacement (LHU/A20NFT - AWD) .

29. Install the exhaust front pipe. Refer to Exhaust Front Pipe Replacement (LBY/A20DTR) Exhaust Front Pipe Replacement (LLU/A16LET) Exhaust Front Pipe Replacement (LBS/A20DTH) Exhaust Front Pipe Replacement (LHU/A20NFT, LAU/A28NER) .

30. Lower the vehicle.

31. Connect the electrical connector of the heated oxygen sensor - sensor 1. Refer to Heated Oxygen Sensor Replacement - Sensor 1 (LLU/A16LET) .

32. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

33. Fill the engine with the appropriate oil type and quantity.

34. Fill the cooling system. Refer to Cooling System Draining and Filling (LAU/A28NER) Cooling System Draining and Filling (LBS/A20DTH) Cooling System Draining and Filling (LHU/A20NFT) .