Orlando

Turbocharger Replacement

Warning: Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury.

Caution: Do not bend the exhaust flex decoupler more than 3 degrees in any direction. Movement of more than 3 degrees will damage the exhaust flex decoupler.

1. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System
2. Remove the engine sight shield. Refer to Engine Sight Shield Replacement .
3. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
4. Remove the turbocharger heat shield. Refer to Turbocharger Heat Shield Replacement .
5. Remove the turbocharger coolant return pipe. Refer to Turbocharger Coolant Return Pipe Replacement : 2.0L Diesel LNP .
6. Remove the turbocharger oil feed pipe. Refer to Turbocharger Oil Feed Pipe Replacement .
7. Remove the charge air cooler inlet air hose. Refer to Charge Air Cooler Inlet Hose Replacement : 2.0L Diesel LNP .
8. Remove the exhaust particulate filter. Refer to Exhaust Particulate Filter Replacement : 2.0L Diesel LNP .
9. Remove the turbocharger coolant feed pipe. Refer to Turbocharger Coolant Feed Pipe Replacement : 2.0L Diesel LNP .
10. Disconnect the exhaust temperature sensor position 1 wiring harness plug. Refer to Exhaust Temperature Sensor Replacement - Position 1 .



11. Remove the charge air control vacuum hose (5) from the turbocharger (1).
12. Disconnect turbocharger wastegate actuator wiring harness plug.
13. Remove the turbocharger oil return pipe. Refer to Turbocharger Oil Return Pipe Replacement .
14. Remove the 4 exhaust turbocharger inlet pipe nuts (2, 4).
15. Remove the turbocharger (1).
16. Remove the turbocharger gasket (3).
17. Remove the exhaust temperature sensor position 1 from the turbocharger. Refer to Exhaust Temperature Sensor Replacement - Position 1 .

1. Install the exhaust temperature sensor position 1 to the turbocharger. Refer to Exhaust Temperature Sensor Replacement - Position 1 .



2. Install the turbocharger (1) to the exhaust manifold. Use a NEW gasket (3).

Caution: Refer to Fastener Caution in the Preface section.

3. Install the exhaust turbocharger inlet pipe nuts (2, 4) and tighten to 30 N·m (22 lb ft).
4. Install the turbocharger oil return pipe. Refer to Turbocharger Oil Return Pipe Replacement .
5. Connect the turbocharger wastegate actuator wiring harness plug.
6. Install the charge air control vacuum hose (5) to the turbocharger (1).
7. Connect the exhaust temperature sensor position 1 wiring harness plug. Refer to Exhaust Temperature Sensor Replacement - Position 1 .
8. Install the turbocharger coolant feed pipe. Refer to Turbocharger Coolant Feed Pipe Replacement : 2.0L Diesel LNP .
9. Install the exhaust particulate filter. Refer to Exhaust Particulate Filter Replacement : 2.0L Diesel LNP .
10. Install the charge air cooler inlet air hose. Refer to Charge Air Cooler Inlet Hose Replacement : 2.0L Diesel LNP .
11. Install the turbocharger oil feed pipe. Refer to Turbocharger Oil Feed Pipe Replacement .
12. Install the turbocharger coolant return pipe. Refer to Turbocharger Coolant Return Pipe Replacement : 2.0L Diesel LNP .
13. Install the turbocharger heat shield. Refer to Turbocharger Heat Shield Replacement .
14. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
15. Install the engine sight shield. Refer to Engine Sight Shield Replacement .
16. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .