For 1990-2009 cars

### Removal Procedure

1. Drain the cooling system. Refer to Cooling System Draining and Filling.
2. Remove the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement.
3. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
4. Remove the charge air cooler pipe bolts at the turbocharger.
5. Remove the charge air cooler pipe from the turbocharger.
6. Remove the air conditioning (A/C) evaporator hose assembly. Refer to Air Conditioning Evaporator Hose Assembly Replacement.
7. Remove the A/C rear condenser tube. Refer to Condenser Tube Replacement.
8. Remove the brake vacuum booster vacuum hose from the booster. Refer to Vacuum Brake Booster Check Valve and/or Hose Replacement.
9. Unbolt the transmission shiftier bracket from the transmission and leave cables attached and position aside.
10. Remove the turbocharger heat shield bolts (1) and shield.
11. Remove the catalytic converter. Refer to Catalytic Converter Replacement.
12. Remove the heated oxygen sensor. Refer to Heated Oxygen Sensor 1 Replacement.
13. Remove the turbocharger exhaust pipe heat shield bolts (1).
14. Remove the turbocharger exhaust pipe heat shield (2).
15. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
16. Remove the turbocharger exhaust pipe nuts (1).
17. Remove the turbocharger exhaust pipe (2).
18. Remove the turbocharger bracket bolt (1).
19. Remove the turbocharger bracket bolt (2) and bracket (3).
20. Remove the turbocharger brace bolts (4).
21. Remove the turbocharger brace nut (5) and brace (6).
22. Lower the vehicle.
23. Disconnect the engine wiring harness electrical connector from the turbocharger wastegate solenoid valve.
24. Reposition the vacuum hose clamp (5) at the turbocharger.
25. Remove the vacuum hose from the turbocharger.
26. Remove the engine wiring harness clip (1) from the turbocharger coolant feed pipe.
27. Remove the turbocharger coolant feed pipe bolt (1) at the turbocharger.
28. Remove and discard the turbocharger coolant feed pipe gasket.
29. Remove the turbocharger coolant feed pipe bolt (3) from the cylinder head.
30. Reposition the turbocharger coolant feed pipe out of the way.
31. Remove the positive crankcase ventilation (PCV) pipe (1) from the turbocharger. Reposition the PCV pipe (with fitting) out of the way. Refer to Metal Collar Quick Connect Fitting Service.
32. Remove the thermostat outlet housing and pipe. Refer to Engine Coolant Thermostat Housing Replacement.

Caution: Do not twist the turbocharger oil feed pipe. Twisting of the feed pipe will result in the collapse and deformation of the plastic pipe, restricting oil flow and causing turbocharger damage. During turbocharger replacement, gently push the oil feed pipe towards the front of the engine to clear the turbocharger. Assistance may be required to keep the pipes clear of the turbocharger during removal or installation.

33. Remove the turbocharger oil feed pipe bolts and pipe (1).
34. Remove and discard the turbocharger oil feed pipe gaskets.
35. Remove the turbocharger coolant return pipe bolts and pipe (1).
36. Remove and discard the turbocharger coolant return pipe gaskets.
37. Remove the turbocharger nuts (2).
38. Remove the turbocharger from the exhaust manifold studs while also removing the turbocharger oil return hose from the engine block.
39. Remove and discard the turbocharger gasket (1) and oil return hose O-ring seal (3).
40. If replacing the turbocharger, perform the following steps otherwise proceed to the step 7 in the Installation Procedure.
41. Remove the turbocharger oil return hose bolts (2) and hose from the turbocharger.
42. Remove and discard the turbocharger oil return hose gasket (1).
43. Reposition the vacuum hose clamps (1, 2, and 3) at the turbocharger wastegate solenoid valve.
44. Remove the vacuum hoses from the turbocharger wastegate solenoid valve.
45. Gently push back the turbocharger wastegate solenoid valve retainer (4) and remove the turbocharger wastegate solenoid valve from the bracket.

### Installation Procedure

1. If replacing the turbocharger, perform the following steps otherwise proceed to step 7.
2. Install the turbocharger wastegate solenoid valve to the bracket until the retainer (4) clips into place.
3. Install the vacuum hoses to the turbocharger wastegate solenoid valve.
4. Position the vacuum hose clamps (1, 2, and 3) at the turbocharger wastegate solenoid valve.
5. Position a NEW turbocharger oil return hose gasket (1) on the turbocharger oil return hose.

Caution: Refer to Fastener Caution in the Preface section.

6. Install the turbocharger oil return hose and bolts (2) and tighten to 10 N·m (89 lb in).
7. Install NEW gaskets onto the turbocharger coolant return pipe fittings.
8. Install the turbocharger coolant return pipe (1) and bolts and tighten to 35 N·m (26 lb ft).
9. Install the thermostat outlet housing and pipe. Refer to Engine Coolant Thermostat Housing Replacement.
10. Install a NEW turbocharger gasket (1) onto the exhaust manifold studs.
11. Lubricate and install a NEW turbocharger oil return hose O-ring seal (3).
12. Install the turbocharger oil return hose to the engine block while also installing the turbocharger to the exhaust manifold studs.
13. Install the turbocharger nuts (2) and tighten to 35 N·m (26 lb ft).
14. Install NEW gaskets onto the turbocharger oil feed pipe fittings.
15. Install the turbocharger oil feed pipe (1) and bolts and tighten the bolts to 32 N·m (24 lb ft).
16. Position the PCV pipe (with fitting) and install the PCV fitting to the turbocharger.
17. Position the turbocharger coolant feed pipe to the turbocharger.
18. Install NEW gaskets onto the turbocharger coolant feed pipe fitting.
19. Install the turbocharger coolant feed pipe bolt (1) at the turbocharger and tighten the bolt to 35 N·m (26 lb ft).
20. Install the turbocharger coolant feed pipe bolt (3) to the cylinder head and tighten the bolt to 10 N·m (89 lb in.
21. Install the engine wiring harness clip (1) to the turbocharger coolant feed pipe.
22. Install the vacuum hose to the turbocharger.
23. Position the vacuum hose clamp (5) at the turbocharger.
24. Connect the engine wiring harness electrical connector to the turbocharger wastegate solenoid valve.
25. Install the turbocharger brace (6) and brace nut (5) and tighten to 50 N·m (37 lb ft).
26. Install the turbocharger brace bolts (4) and tighten the nut to 50 N·m (37 lb ft).
27. Install the turbocharger bracket (3) and bracket bolt (2) and tighten the nut to 25 N·m (18 lb ft).
28. Install the turbocharger bracket bolt (1) and tighten to 25 N·m (18 lb ft).
29. Install the turbocharger exhaust pipe (2).
30. Install the turbocharger exhaust pipe nuts (1) and tighten to 50 N·m (37 lb ft).
31. Install the turbocharger exhaust pipe heat shield (2).
32. Install the turbocharger exhaust pipe heat shield bolts (1) and tighten the nut to 10 N·m (89 lb in).
33. Install the transmission shiftier bracket with the cables to the transmission.
34. Install the brake vacuum booster vacuum hose to the booster. Refer to Vacuum Brake Booster Check Valve and/or Hose Replacement.
35. Install the A/C rear condenser tube. Refer to Condenser Tube Replacement.
36. Install the A/C evaporator hose assembly. Refer to Air Conditioning Evaporator Hose Assembly Replacement.
37. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.
38. Install the heated oxygen sensor. Refer to Heated Oxygen Sensor 1 Replacement.
39. Install the catalytic converter. Refer to Catalytic Converter Replacement.
40. Lower the vehicle.
41. Install the turbocharger heat shield and bolts (1) and tighten the bolts to 10 N·m (89 lb in).
42. Install the charge air cooler pipe and gasket to the turbocharger.
43. Install the charge air cooler pipe bolts at the turbocharger and tighten the bolts to 22 N·m (16 lb ft).
44. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
45. Install the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement.
46. Fill the cooling system. Refer to Cooling System Draining and Filling.