Wastegate Solenoid and Exhaust Elbow – Remove and Install


Wastegate Solenoid

Removal Procedure


Follow Steps to disconnect the wire lead (1).
Disconnect the wire lead (1) from the harness assembly.
If the harness assembly (1) is secured with a cable tie, remove the cable tie.
Remove the wire lead (1) from the tube assembly (2). The wire lead is secured to the tube assembly with clips.
Disconnect the tube assembly (2) from the wastegate solenoid (3).
Disconnect the tube assembly (4) from the wastegate solenoid (3). If the tube assembly (4) is secured with tube clips, loosen the fasteners for the tube clips. The tube clipsmust be loose in order to release the tube assembly from the wastegate solenoid.
Remove the two setscrews (5) and remove the wastegate solenoid (3) from the cylinder block.
Plug or cap all open ports and tube assemblies with new plugs or caps.

Installation Procedure

Remove the plugs or caps from all ports and tube assemblies.
Loosely install the wastegate solenoid (3) to the tube assembly (2).
Loosely install the tube assembly (4) to the wastegate solenoid (3).
Install the two setscrews (5) to the wastegate solenoid (3). Tighten the setscrews (5) to a torque of 44 N·m (32.5 lb ft).
Tighten tube assemblies (2) and (4) to a torque of 22 N·m (16 lb ft).
If the tube assembly (4) is secured with tube clips, tighten the fasteners for the tube clips. Tighten M8 fasteners to a torque of 22 N·m (16 lb ft). Tighten M10 fasteners to a torque of 44 N·m (32.5 lb ft).
Follow Steps in order to connect the wire lead (1).
Install the wire lead (1) to the tube assembly (2).
Connect the wire lead (1) to the harness assembly for the engine.
If the wire lead (1) is secured with a cable tie, install a new cable tie.

Exhaust Elbow

Removal Procedure

Remove the exhaust pipe.


Remove the setscrews (1) that secure the exhaust elbow (2) to the engine. Remove the exhaust elbow (2) from the engine.
Remove the coupling (4) that connects exhaust elbow (2) to the turbocharger (3).
Some types of exhaust elbow have a separate support bracket. If necessary, remove the setscrews that secure the bracket to the exhaust elbow. Remove the support bracket.

Installation Procedure

Thoroughly clean the exhaust elbow (2), the coupling (4) and the outlet of the turbocharger (3). Inspect the sealing faces of the components for wear or damage. Replace any components that are worn or damaged.
Install the coupling (4) to the exhaust elbow (2).
Align the coupling (4) to the outlet of the turbocharger (3). Install the assembly of the coupling (4) and the exhaust elbow (2) to the turbocharger (3).
Some types of exhaust elbow have a separate support bracket. If necessary, install the bracket and install the setscrews that secure the bracket to the exhaust elbow finger tight. Install setscrews (1) finger tight.
Ensure that the coupling (4) is fully engaged into the outlet of the turbocharger (3) and into the exhaust elbow (2). Ensure that the gap between the turbocharger and the exhaust elbow is evenly spaced.
Tighten the setscrews (1) to a torque of 44 N·m (33 lb ft).
If the exhaust elbow has a separate support bracket, tighten the setscrews that secure the bracket to the exhaust elbow to a torque of 44 N·m (33 lb ft).
Install the exhaust pipe.