Turbocharger replacement

/ 9-5 (9650) / 2011 / 2. Engine / Basic engine, V6 / Adjustment/replacement / Turbocharger replacement

Removal Procedure

1.	Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement .

2.	Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .

3.	Remove the upper intake manifold. Refer to Upper Intake Manifold Replacement .

4.

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) .

5.	Note Do NOT remove the exhaust manifold - right side. Remove the exhaust manifold brace - right side. Refer to Exhaust Manifold Replacement - Right Side (LAU/A28NER) .

6.	Remove the charge air cooler outlet air tube. Refer to Charge Air Cooler Outlet Air Tube Replacement .

7.	Remove the generator. Refer to Generator Replacement (Diesel) Generator Replacement (LAU/A28NER) Generator Replacement (LLU/A16LET) Generator Replacement (LHU/A20NFT) .

8.	Remove the positive crankcase ventilation tube from the oil level indicator tube.

9.	Remove the secondary air injection inlet pipe. Refer to Secondary Air Injection Pump Pipe Replacement .

10.	Remove the secondary air injection outlet pipe. Refer to Secondary Air Injection Pump Pipe Replacement .

11.	Remove the oil level indicator and tube. Refer to Oil Level Indicator Tube Replacement .

12.	Remove the turbocharger coolant feed pipe (1).

13.	Remove the 4 exhaust front manifold heat shield fasteners (1).

14.	Remove the exhaust front manifold heat shield (2).

15.	Remove the 3 exhaust manifold brace fasteners (1).

16.	Remove the exhaust turbocharger inlet pipe fasteners (1).

17.	Remove the exhaust turbocharger inlet pipe (2).

18.	Remove the charge cooler inlet 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) .

19.	Remove the 2 turbocharger oil feed pipe fittings (2, 6) and gaskets (1, 3).

20.	Remove the turbocharger oil feed pipe fastener (4).

21.	Remove the turbocharger oil feed pipe (5).

22.	Remove the 2 turbocharger oil return pipe fasteners (5).

23.	Remove the turbocharger oil return pipe fastener (3).

24.	Remove the turbocharger oil return pipe (4).

25.	Remove the turbocharger oil return pipe gasket (1).

26.	Remove the turbocharger oil return pipe seal (2).

27.	Remove the positive crankcase ventilation tube (1).

28.	Remove the turbocharger fastener (2).

29.	Remove the turbocharger (3).

Installation Procedure

1.	Refer to Fastener Caution . Install the turbocharger (3).

2.	Install the turbocharger bracket (2) and tighten to 65 Nm (48 lb ft) .

3.	Install the positive crankcase ventilation tube (1).

4.	Install the NEW turbocharger oil return pipe seal (2).

5.	Install the NEW turbocharger oil return pipe gasket (1).

6.	Install the turbocharger oil return pipe (4).

7.	Install the 2 turbocharger oil return pipe fasteners (5) and tighten to 14 Nm (11 lb ft) .

8.	Install the turbocharger return oil hose bracket (3) and tighten to 65 Nm (48 lb ft) .

9.	Install the turbocharger oil feed pipe (5).

10.	Install the NEW turbocharger oil feed pipe fastener gaskets (1, 3).

11.	Install the turbocharger oil feed pipe fastener (4).

12.	Install the 2 turbocharger oil feed pipe fittings (2, 6) and tighten the banjo screws to 30 Nm(22 lb ft) .

13.	Install the charge air cooler inlet 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) .

14.	Install a NEW exhaust turbocharger inlet pipe gasket.

15.	Install the exhaust turbocharger inlet pipe (2).

16.	Install the turbocharger intake manifold fasteners (1) and tighten to 30 Nm (22 lb ft) .

17.	Install the 3 fasteners to the exhaust manifold(1) and tighten to 30 Nm (22 lb ft) .

18.	Install the exhaust front manifold heat shield (2).

19.	Install the 4 exhaust front manifold heat shield fasteners (1) and tighten to 10 Nm (89 lb in) .

20.	Install the turbocharger coolant delivery pipe (1) and tighten the M12 to 30 Nm (22 lb ft) and then the M14 to 35 Nm (26 lb ft) .

21.	Install the oil level indicator and tube. Refer to Oil Level Indicator Tube Replacement .

22.	Install the secondary air injection outlet pipe. Refer to Secondary Air Injection Pump Pipe Replacement .

23.	Install the secondary air injection inlet pipe. Refer to Secondary Air Injection Pump Pipe Replacement .

24.	Install the positive crankcase ventilation tube to the oil level indicator tube.

25.	Install the generator. Refer to Generator Replacement (Diesel) Generator Replacement (LAU/A28NER) Generator Replacement (LLU/A16LET) Generator Replacement (LHU/A20NFT) .

26.	Install the charge air cooler outlet air tube. Refer to Charge Air Cooler Outlet Air Tube Replacement .

27.	Install the exhaust manifold brace - right side. Refer to Exhaust Manifold Replacement - Right Side (LAU/A28NER) .

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 upper intake manifold. Refer to Upper Intake Manifold Replacement .

30.	Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .

31.	Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .

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