Stay tuned. David_K and I are collaborating on a comprehensive article on our experience with this upgrade...


For now i will lock the post.

 

Tools needed to complete this removal/installation

Penetrating oil
Flat head screw driver
Phillips screw driver
Craftsman or similar 3/8" torque wrench
3/8" hand rachet
Metric and English socket set
Air compressor (Not required but awful handy)
3/8" Impact wrench (not required but awful handy)
3/8" air rachet (not required but awful handy)
3/8" extension bar set
Needle nose pliars
Blunt nose pliars
Oil Catch tank
Antifreeze catch tank
Two hand vices, preferably with rubber grips (use these to pinch off the two coolant lines)

I'm positive I've left something out and will fill in the blanks later.

 

Removal of the Turbocharger

NOTE: Wait until the engine is completely cool before beggining this procedure.

1. Drain the cooling system.
1a. Move a large container under the radiator drain to catch the coolant. The coolant can be drained by detaching the lower radiator hose from the radiator.
2. Raise the vehicle and support it on jackstands.
3. Remove the engine compartment undercover.
4. Remove the air conditioning compressor from the mounting bracket and set it aside without disconnecting the refrigerant hoses.
5. Remove the turbocharger support bracket.
6. Losen the hose clamps and disconnect the air inlet and outlet ducts from the turbocharger.
7. Remove the bolts and disconnect the oil return line pipe from the turbo charger.
8. Lossen the oil supply union bolt from the turbocharger. Remove the bracket bolt and disconnect the oil supply pipe from the turbocharger.
9. Disconnect the vacuum hose from the wastegate actuator and remove the coolant line bracket bolt.
10. Disconnect the required hoses and electrical connectors at the air filter assembly and remove the air filter housing and the duct from the air filter housing to the turbocharger.
11. Disconnect the crankcase ventilation hose from the valve cover and heat shield. Remove the oil line braket bolt and remove the heat shield.
12. Loosen the clamps, remove the bracket bolts and remove the Turbocharger oulet pipe and elbow.
13. Loosen the coolant return pip union bolt at the turbocharger. Remove the bracket bolt and disconnect the coolant return pipe from the turbocharger. Be sure to recover the sealing washers.
14. Remove the nuts connecting the downpipe the the cat pipe.
15. Remove the nuts connecting the cat pipe to the turbocharger. Remove the exhaust support bolts and lower the exhaust.
16. Remove the turbocharger-to-exhaust manifold bolts. Lower the turbocharger, tilt it to the side, loosen the coolant supply pipe union bolt and disconnect the coolant supply pipe from the turbocharger.
17. Remove the turbocharger from the engine compartment.



16.