Jeep replace turbo, oil cooler & hose, engine mount, heater hose

Replacing a turbocharger can be challenging. Modern car engine bays are compact and many turbo units are fitted in confined spaces where tool use is difficult. Some vehicle manufacturers recommend engine removal to replace a turbocharger.

To replace a typical turbo you’ll first need to remove:

• Remove all air intake ducting
• Remove turbo heat shields – With the covers off you’ll get a better view of exhaust clamp, oil and coolant lines.
• Remove boost sensor wiring
• Mark and remove actuator vacuum lines/wiring plug
• Remove and clamp off coolant lines (not all turbos are water cooled)
• Remove oil lines and clamp off
• Remove turbo assembly stabilizer supports
• Remove exhaust to turbo fasteners

Here’s a list of tools that make life easier, note I haven’t listed all the regular wrenches and screwdrivers, etc. 

• Hose clamp remover
• Creeper
• Axle stands
• Swivel sockets
• Adaptors
• Extra long extensions
• Ratcheting wrenches
• LED lamp
• Mirror
• Oil line clamps

Tips for fitting the new turbo:

• Clean all exhaust mating surfaces
• Keep blanking caps on new turbo until turbo in place
• Replace exhaust gaskets
• Torque exhaust to spec – overtightening can lead to broken header/manifold bolts as heat expands the metal later
• Fill turbo oil port with fresh oil before attaching oil line
• Fit new oil feed line and gaskets
• Check oil drain line and replace if damaged
• Fit new coolant line gaskets if applicable
• Fit all heat shields, they are important
• Check intake ducting and intercooler for debris
• Check vacuum hoses and wiring connectors damage
• Spin turbo shaft by hand before fitting intake ducting
• Replace oil and filter
• Clean air box thoroughly and replace air filter