Turbocharger: Service and Repair

Turbocharger

Turbocharger (View 1 of 3)










Turbocharger (View 2 of 3)










Turbocharger (View 3 of 3)









Removal

NOTICE: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.

NOTICE: The turbocharger wastegate actuator locknuts are not adjustable. Do not attempt to adjust the wastegate actuator locknuts or engine damage may occur.

NOTICE: Do not disassemble the turbocharger. Doing so may cause turbocharger or engine damage to occur.

1. With the vehicle in NEUTRAL, position it on a hoist.

2. If equipped, remove the splash shield.

3. Remove the catalytic converter - 2.0L Gasoline Turbocharged Direct Injection (GTDI).

4. Remove the lower Charge Air Cooler (CAC) inlet tube and the turbocharger inlet pipe.

5. Drain the cooling system.

6. Remove the water outlet tube and the water inlet hose assembly.
- Disconnect the 2 water outlet tube clamps.

- Remove the 2 bolts and discard the linked washers.






7. Disconnect the 2 turbocharger vacuum hose connections.





8. Remove the 2 cylinder block oil to engine turbocharger pipe bolts.
- Discard the cylinder block oil to engine turbocharger pipe and gaskets.






9. Disconnect the 2 turbocharger electrical connectors.





10. Disconnect the 2 turbocharger vacuum hoses connections.





11. Remove the 2 bolts and the heat shield.





12. Remove the 4 bolts and the turbocharger oil drain tube.
- Discard the turbocharger oil drain tube and gaskets.






13. Remove the 4 nuts and the turbocharger.
- Discard the 4 nuts and gasket.






Installation

1. NOTE: Tighten the 4 new turbocharger nuts in the sequence shown.
Install a new gasket, the turbocharger and 4 new nuts. Tighten the nuts in the sequence shown.

- Tighten to 50 Nm (37 lb-ft).






2. NOTICE: Install a new turbocharger oil drain tube and gaskets. By not doing so, the turbocharger oil drain tube may leak and cause engine damage.

Install the 4 bolts, a new turbocharger oil drain tube and 2 new gaskets.
- Tighten to 10 Nm (89 lb-in).






3. Install the 2 bolts and the heat shield.
- Tighten to 10 Nm (89 lb-in).






4. Connect the 2 turbocharger vacuum hose connections.





5. Connect the 2 turbocharger electrical connectors.





6. NOTE: Install a new cylinder block oil to engine turbocharger pipe and new gaskets.
Install a new cylinder block oil to engine turbocharger pipe, new gaskets and the 2 bolts.

- Tighten to 25 Nm (18 lb-ft).






7. Connect the 2 vacuum hose connections to the turbocharger.





8. NOTE: Both water outlet tube clamps must be installed between the 2 paint stripes on hoses.
Install the water outlet tube and the water inlet hose assembly.

- Connect the 2 water outlet tube clamps.

- Install the 2 bolts and new linked washers.
- Tighten to 28 Nm (21 lb-ft).







9. Fill and bleed the cooling system.

10. Install the lower Charge Air Cooler (CAC) inlet tube and the turbocharger inlet pipe.

11. Install the catalytic converter - 2.0L Gasoline Turbocharged Direct Injection (GTDI).

12. If equipped, remove the splash shield.