REMOVAL & INSTALLATION

CAUTION
In all cases, allow the engine to cool at least 3–4 hours before attempting any work on the turbocharger. The exhaust and turbocharger retain heat long after the engine is shut off.

2.3L Diesel

1. Disconnect the negative battery cable.
2. Disconnect the exhaust pipe from the turbocharger and remove the gasket. Remove the heat shield.
3. Remove the bolts holding the inlet fitting to the inlet manifold. Loosen the hose clamps and remove the fitting; remove the rubber connecting hose.
4. Loosen the hose clamps from the oil return line and remove it.
5. Carefully disconnect the oil supply pipe from the top of the turbocharger.
6. Disconnect the vacuum hose to the top of the wastegate actuator. Remove the wastegate actuator mounting bolts.
7. Remove the bolts holding the turbocharger to the exhaust flange. Remove the turbocharger and discard the gasket.
8. Immediately after removing the turbocharger, plug the intake and exhaust ports and the oil ports with clean, lint–free cloths or crumpled paper. The turbocharger MUST be protected from dirt and grit; place the unit in a protected location away from the work area.

   WARNING
   Do not disassemble the turbocharger unit after removal.

   To install:

9. Remove the plugs from the turbocharger passages and install the turbocharger with a new gasket onto the exhaust manifold. Tighten the nuts evenly — refer to the illustration.
10. Install the wastegate actuator mounting bolts and tighten to 10 ft. lbs. (14 Nm). Reconnect the upper vacuum hose.
11. Connect the oil return line; make certain the clamp is secure.
12. Pour clean engine oil into the oil supply port to pre–lubricate the turbocharger. Install the oil supply line and tighten it carefully.
13. Install the rubber connecting hose on the inlet fitting. Use a new gasket and attach the inlet fitting to the intake manifold.
14. Use a new gasket and install the exhaust pipe to the bottom of the turbocharger. Install the heat shield.
15. Start the engine, listening carefully for any sign of unusual noise from either the manifolds or the turbocharger. Watch the oil pressure indicator for any sign of incorrect pressure.