NHTSA ID Number: 10246431
Manufacturer Communication Number: ITB22-038C
TSB/Document Date: 2023-12-08
Summary
TURBOCHARGER REPLACEMENT PROCEDURE This bulletin has been amended. See AMENDMENT HISTORY on the last page. Please discard previous versions of this bulletin.
Reattach the oil feed tube mounting bracket with bolt (Figure 56) and torque to
specification.
Bolt torque: 9.0 N•m (0.92 kg-m, 80 in.-lb)
Oil feed tube mounting
bracket bolt
Eye bolt
Figure 56
87.
Align the turbocharger Air Inlet Hose 1 (bank 1) with the turbocharger output, and then
slide the turbocharger onto its mounting studs.
Leave the turbocharger Air Inlet Hose 1 (bank 1) clamp loose at this time.
Replace the turbocharger to cylinder head gasket with a new part from PARTS
INFORMATION.
Air Inlet Hose
1 (bank 1)
Figure 57
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ITB22-038C
88.
Reconnect the oil return hose and spring clamp.
Figure 58
89.
Install all four (4) turbocharger mount nuts, and then torque them in the order (from 1
to 6) shown in Figure 59.
Nut torque: 30.5 N•m (3.1 kg-m, 22 ft-lb)
90.
Align the Catalyst Converter (bank 1) with 2nd Catalyst Converter (bank 1) studs and
install the nuts finger tight. See PARTS INFORMATION for new gasket.
91.
Reattach the Catalyst Converter (bank 1) to the turbocharger outlet, and then lightly
tighten the band clamp bolt enough to align catalyst, but allow it to rotate.
Turbocharger
mount nuts (4)
3
1, 5
4
2, 6
Band clamp
bolt
Figure 59
27/62
ITB22-038C
92.
Install the catalyst converter support bracket bolt and torque to specification.
Bolt torque: 47.8 N•m (4.9 kg-m, 35 ft-lb)
Support
bracket bolt
Figure 60
93.
Torque the Catalyst Converter (bank 1) to the turbocharger outlet band clamp bolt to
specification.
94.
Bolt torque: 15 N•m (1.5 kg-m, 11 ft-lb)
Torque the oil feed tube eye bolt to specification.
Bolt torque: 25.0 N•m (2.6 kg-m, 18 ft-lb)
Eye bolt
Oil feed tube
Figure 61
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ITB22-038C
95.
Reinstall the water tube bracket bolt (Figure 62) and torque to specification.
96.
Bolt torque: 9.0 N•m (0.92 kg-m, 80 in.-lb)
Reinstall the coolant hose and its spring clamp (Figure 62).
Water tube
bracket bolt
Figure 62
97.
Reinstall the two (2) exhaust mount bolts shown in Figure 63 finger tight.
Figure 63
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ITB22-038C
98.
Torque the Catalyst Converter (bank 1) to 2nd Catalyst Converter (bank 1) nuts that
were finger tightened, in step 90 on page 27, to specifications.
99.
Nut torque: 44.9 N•m (4.6 kg-m, 33 ft-lb)
Torque the two (2) exhaust mount bolts installed finger tight in step 97 on page 29 to
specification.
Bolt torque: 44.9 N•m (4.6 kg-m, 33 ft-lb)
Catalyst Converter
nuts (3)
Figure 64
100. Reinstall Heat Insulator (upper) with five (5) bolts.
Bolt torque: 9.0 N•m (0.92 kg-m, 80 in.-lb)
Heat Insulator
(upper) bolts (5)
Heat Insulator
(upper)
Figure 65
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ITB22-038C
101. Install a new A/F sensor from PARTS INFORMATION, torque it to specification and
then reconnect its wiring harness connector.
A/F sensor torque: 50 N•m (5.1 kg-m, 37 ft-lb)
A/F sensor
Figure 66
102. Tighten the hose clamp (Figure 67).
103. Reconnect the two (2) hoses (Figure 67).
104. Reconnect the wiring harness connector (Figure 67).
105. If the Turbocharger Exhaust Gas Temperature Sensor (bank 1) wiring harness
connector was disconnected in step 74 on page 22, then reconnect it.
Hose clamp
Hoses (2)
Wiring harness
connector
Figure 67
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ITB22-038C
Remove the Driver (LH) Side Turbocharger
106. Loosen the hose clamp shown in Figure 68. This hose will be detached in step 123 on
page 36.
107. Release the spring clamps and disconnect the three (3) associated hoses, shown in
Figure 68.
108. Disconnect the wiring harness connector shown in Figure 68.
Hoses (3)
Hose clamp
Figure 68
109. Unplug the A/F sensor wiring harness connector, and then remove the A/F sensor
from the turbocharger housing.
A/F sensor
Harness connector
Figure 69
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ITB22-038C
110. If present, unplug the Turbocharger Exhaust Gas Temperature Sensor (Bank 2) wiring
harness connector, and then remove the sensor from the turbocharger housing.
111. Remove the turbocharger Heat Insulator (upper).
Heat Insulator
(upper)
Heatshield
bolts (4)
Figure 70
112. Remove the two (2) nuts that connect the Catalyst Converter (bank 2) to the 2nd
Catalyst Converter (bank 2).
Catalyst Converter
nuts (2)
Figure 71
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ITB22-038C
113. Remove the Catalyst Converter (bank 2) support bracket bolt.
Support
bracket bolt
Figure 72
114. Remove the 2nd Catalyst Converter (bank 2) support bracket bolt.
Support
bracket bolt
Figure 73
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ITB22-038C
115. Loosen the turbocharger assembly mounting nuts in order, from 1 to 4, as shown in
Figure 74.
116. Remove the band clamp bolt.
4
Turbocharger
mount nuts (4)
2
1
3
Band clamp
bolt
Figure 74
117. Detach Catalyst Converter (bank 2) from the turbocharger outlet.
118. Release the spring clamp and disconnect the associated oil return hose shown in
Figure 75.
Figure 75
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ITB22-038C
119. Remove the eye bolt retaining the oil feed tube.
Eye bolt
Figure 76
120. Remove both the A/C High-Pressure Flexible Hose and then the Low-Pressure Pipe 2
from the A/C compressor (Figure 77).
121. Remove the Oil Feed Tube mounting bracket bolt shown in Figure 77.
Low-Pressure
Pipe 2
Oil Feed Tube mounting
bracket bolt
High-Pressure
Flexible Hose
A/C
compressor
Figure 77
122. If present, disconnect the Turbocharger Speed Sensor (Bank 2) wiring harness
connector.
123. Remove the turbocharger from the engine and place it on a clean workbench.
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ITB22-038C
124. Transfer the components from the old to the new turbocharger assembly and torque
to the specifications below.
IMPORTANT: Refer to PARTS INFORMATION for single use parts.
Water tube eye bolt torque: 25.0 N•m (2.6 kg-m, 18 ft-lb)
HINT: One (1) Water tube eye bolt is hidden in Figure 55.
Bracket bolt torque: 9.0 N•m (0.92 kg-m, 80 in.-lb)
Oil return pipe bolt torque: 9.0 N•m (0.92 kg-m, 80 in.-lb)
Heat insulator (lower) bolt torque: 9.0 N•m (0.92 kg-m, 80 in.-lb)
If present, Turbocharger Speed Sensor (bank 2):
o Wiring harness connector bracket to turbocharger torque: 7.0 N•m (0.71 kg-m,
62 in.-lb)
o Wiring harness connector to bracket torque: 2.2 N•m (0.22 kg-m, 19 in.-lb)
Bracket
bolts (2)
Water tube
eye bolts (2)
Heat insulator
(lower) bolts (3).
1 hidden in Figure
Oil return pipe bolts (2).
1 hidden in Figure
Figure 78
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ITB22-038C
Reinstall the Driver (LH) Side Turbocharger
125. If present, reconnect the Turbocharger Speed Sensor (Bank 2) wiring harness
connector.
126. Install and temporarily tighten the eye bolt for the oil feed tube, with a new gasket
(Figure 79).
Eye bolt
Oil feed tube
Figure 79
127. Reattach the Oil Feed Tube mounting bracket bolt (Figure 80), and then torque to
specification.
Bolt torque: 9.0 N•m (0.92 kg-m, 80 in.-lb)
Oil Feed Tube
mounting bracket bolt
A/C
compressor
Figure 80
38/62
ITB22-038C
128. Align the turbocharger Air Inlet Hose 1 (bank 2) with the turbocharger output, and then
slide the turbocharger onto its mounting studs.
Leave the turbocharger Air Inlet Hose 1 (bank 2) clamp loose at this time.
Replace the turbocharger to cylinder head gasket with a new one from PARTS
INFORMATION.
129. Reconnect the wiring harness connector shown in Figure 81.
130. Reconnect the three (3) hoses shown in Figure 81.
Hoses (3)
Wiring harness
connector
Hose clamp
Figure 81
131. Reconnect the oil return hose and spring clamp.
Figure 82
39/62
ITB22-038C
132. Install all four (4) turbocharger mount nuts, and then torque them in the order
(from 1 to 6) shown in Figure 83.
Nut torque: 30.5 N•m (3.1 kg-m, 22 ft-lb)
133. Align the Catalyst Converter (bank 2) with 2nd Catalyst Converter (bank 2) studs and
install the nuts finger tight.
134. Reattach the Catalyst Converter (bank 2) to the turbocharger outlet, and then lightly
tighten the band clamp bolt just enough to align catalyst, but allow it to rotate.
Band clamp will be torqued in step 137 on page 42.
1, 5
Turbocharger
mount nuts (4)
4
3
2, 6
Band clamp
bolt
Figure 83
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ITB22-038C
135. Reinstall the 2nd Catalyst Converter (bank 2) support bracket bolt finger tight.
Support
bracket bolt
Figure 84
136. Reinstall the Catalyst Converter (bank 2) support bracket bolt finger tight.
Support
bracket bolt
Figure 85
41/62
ITB22-038C
137. Torque the Catalyst Converter (bank 2) to the turbocharger outlet band clamp bolt to
specification.
Bolt torque: 15 N•m (1.5 kg-m, 11 ft-lb)
138. Torque the 2nd Catalyst Converter (bank 2) support bracket bolt to specification.
Bolt torque: 47.8 N•m (4.9 kg-m, 35 ft-lb)
139. Torque the Catalyst Converter (bank 2) support bracket bolt to specification.
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TSB/Document ID: ITB22-038C
Replacement Service Bulletin Number:
MFR Communication Date: 2023-11-06
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING:ENGINE:GASOLINE:TURBO/SUPERCHARGER
MFR Component System:
MFR Component Subsystem:
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