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Hugh Cain
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1 Page 1 of 6 Fuel Charging and Controls - Turbocharger - 2.7L V6 - TdV6 - Turbocharger RH Removal and Installation Special Tool(s) Engine support beam Engine lifting brackets Removal 1. Remove the intake air shutoff throttle. For additional information, refer to: Intake Air Shutoff Throttle (303-04C Fuel Charging and Controls - 2.7L V6 - TdV6, Removal 2. Remove the fuel injector soundproofing. 3. Remove the generator. For additional information, refer to: Generator - 2.7L V6 - TdV6 ( Generator and Regulator, Removal 4. Remove the starter motor. For additional information, refer to: Starter Motor - 2.7L V6 - TdV6 ( Starting System, Removal and 5. Remove the cowl panel grille. For additional information, refer to: Cowl Panel Grille ( Front End Body Panels, Removal and 6. Detach the right-hand air cleaner outlet tube from the timing cover. 7. Remove the right-hand catalytic converter. For additional information, refer to: Catalytic Converter - 2.7L V6 - TdV6 ( Exhaust System, Removal 8. Detach the turbocharger outlet tube connecting hose. 9. Remove the turbocharger outlet tube. 10. Remove the air cleaner outlet tube. 1. Detach the air cleaner outlet tube to turbocharger retaining clip. 2. Detach the air cleaner outlet tube to breather hose retaining clip. Remove the air cleaner outlet tube. 11. Remove and discard the catalytic converter retaining stud.

Page 2 of 6 12. Remove the turbocharger heatshield. 13. Remove the turbocharger support bracket. 14. Disconnect the oil return tube from the turbocharger. Remove and discard the gasket. 15.

2 Page 2 of Remove the turbocharger heatshield. 13. Remove the turbocharger support bracket. 14. Disconnect the oil return tube from the turbocharger. Remove and discard the gasket. 15. Remove the oil return tube retaining plate. 16. Remove the oil return tube. Remove and discard the O-ring seal. 17. Lower the vehicle. 18. Fit the front engine lifting brackets 19. Fit the engine support beam.

3 Page 3 of Detach the right-hand engine mounting. 21. Raise the engine. 22. Remove the right-hand engine mounting retaining nut. 23. Remove the right-hand engine mounting bracket. 24. Remove the right-hand engine mounting. 25. Disconnect the turbocharger solenoid electrical connector. 26. Lower the vehicle. 27. Disconnect the turbocharger oil supply tube. Remove and discard the sealing washers. 28. Raise the vehicle. 29. Remove the turbocharger. Discard the turbocharger retaining nuts.

4 Page 4 of 6 Remove and discard the turbocharger to exhaust manifold retaining studs. Installation 1. Install the turbocharger. Install new turbocharger to exhaust manifold retaining studs. Install new turbocharger retaining nuts. Tighten to 23 Nm. 2. Lower the vehicle. 3. Connect the turbocharger oil supply tube. Install new sealing washers. Tighten to 30 Nm. 4. Raise the vehicle. 5. Connect the turbocharger solenoid electrical connector. 6. Install the right-hand engine mounting. 7. Install the right-hand engine mounting bracket. Tighten to 90 Nm. 8. Tighten to 63 Nm. 9. Lower the vehicle. 10. Lower the engine.

5 Page 5 of Tighten to 63 Nm. 12. Remove the engine support beam. 13. Remove the front engine lifting eyes. 14. Raise the vehicle. 15. Install the oil return tube. Install a new O-ring seal. 16. Install the oil return tube retaining plate. Tighten to 10 Nm. 17. Connect the oil return tube to the turbocharger. Install a new gasket. 18. Install the turbocharger support bracket. Tighten to 23 Nm. 19. Install the turbocharger heatshield. Tighten to 10 Nm.

6 Page 6 of Install a new catalytic converter retaining stud. 21. Install the air cleaner outlet tube. 1. Attach the air cleaner outlet tube to turbocharger retaining clip. 2. Attach the air cleaner outlet tube to breather hose retaining clip. 22. Install the right-hand turbocharger outlet tube. 23. Attach the right-hand turbocharger outlet tube connecting hose. 24. Install the right hand catalytic converter. For additional information, refer to: Catalytic Converter - 2.7L V6 - TdV6 ( Exhaust System, Removal 25. Attach the right-hand air cleaner outlet tube to the timing cover. 26. Install the starter motor. For additional information, refer to: Starter Motor - 2.7L V6 - TdV6 ( Starting System, Removal and 27. Install the generator. For additional information, refer to: Generator - 2.7L V6 - TdV6 ( Generator and Regulator, Removal 28. Install the cowl panel grille. For additional information, refer to: Cowl Panel Grille ( Front End Body Panels, Removal and 29. Install the fuel injector soundproofing. 30. Install the intake air shutoff throttle. For additional information, refer to: Intake Air Shutoff Throttle (303-04C Fuel Charging and Controls - 2.7L V6 - TdV6, Removal

Exhaust Gas Recirculation Valve, Replace J S file://c:\program Files\cosids\DATA\TMP\ rtf.html. Remove

$Exhaust Gas Recirculation Valve, Replace J S file://c:\program Files\cosids\DATA\TMP\ rtf.html. Remove$ 1 Page 1 of 20 Exhaust Gas Recirculation Valve, Replace J982500 Remove 1. Disconnect battery negative lead 2. Disconnect hose (1) from oil filler on air cleaner assembly, then move to one side Release