Buick Encore: Turbocharger replacement

Turbocharger replacement - Removal Procedure

Special Tools

EN-49942 Holding Wrench

For equivalent regional tools, refer to Special Tools.

Removal Procedure

1. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Drain the cooling system. Refer to Cooling System Draining and Filling .
3. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
4. Disconnect the positive crankcase ventilation pipe from turbocharger.
5. Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement (LUV) .

Fig. 196: Turbocharger Wastegate Regulator Solenoid Valve Wiring Harness Connector And Retaining Clip

6. Disconnect the turbocharger wastegate regulator solenoid valve wiring harness connector (1) and unclip wiring harness from retainer clip (2).

Fig. 197: Turbocharger Oil Feed Pipe Components

7. Remove the turbocharger oil feed pipe hollow screw (4).
8. Remove and DISCARD the 2 seal rings (1) and (3).
9. Remove the turbocharger oil feed pipe bolt (5).

NOTE: Close the screw bore in the turbocharger in order to avoid contamination.

10. Remove the turbocharger oil feed pipe (2).
11. Loosen the turbocharger coolant return hose clamp and remove the turbocharger coolant return hose (6) from the oil cooler inlet pipe.
12.  Remove the turbocharger coolant return pipe bolt (7).
13. Remove the charge air cooler inlet air hose from the turbocharger. Refer to Charge Air Cooler Inlet Air Hose Replacement

NOTE: It is not necessary to evacuate the air conditioning system when repositioning the compressor.

14. Remove the air conditioning compressor bracket and reposition the air conditioning compressor. Refer to Air Conditioning Compressor Bracket Replacement (LUJ, LUV) .

Fig. 198: Ratchet Wrench And Holding Wrench

15. Install the EN-49942 holding wrench (2) to the turbocharger coolant feed pipe. Guide a ratchet wrench (1) along with an extension through EN-49942 holding wrench to the turbocharger coolant feed pipe hollow screw.

Fig. 199: Ratchet Wrench, Holding Wrench And Coolant Feed Pipe

NOTE: EN-49942 holding wrench (2) should be installed to turbocharger coolant feed pipe as shown. The holding wrench should be installed to avoid twist of the turbocharger coolant feed pipe during the loosening procedure.

16. Loosen the turbocharger coolant feed pipe hollow screw with ratchet wrench and extension (1).
17.  Remove the turbocharger coolant feed pipe hollow screw.
18. Remove and DISCARD the 2 seal rings.
19. Remove the warm up three-way catalytic converter. Refer to Warm Up Three-Way Catalytic Converter Replacement (2H0, LUV) .

Fig. 200: Turbocharger Oil Return Pipe Bolts

20. Remove the 2 turbocharger oil return pipe bolts (1) from turbocharger.
21.  Remove the turbocharger oil return pipe from the turbocharger.
22. Remove and DISCARD the gasket.

NOTE: It is only necessary to move the wastegate actuator aside enough to access the manifold nuts.

23. Remove the wastegate actuator nuts and set aside.

Fig. 201: Turbocharger Nuts

24. Remove and DISCARD the 8 turbocharger nuts (1).

Fig. 202: Turbocharger Assembly And Gasket

25. Remove the turbocharger assembly (1).
26. Remove and DISCARD the turbocharger gasket (2).
27. Remove the assembly parts from the turbocharger as necessary. Refer to Turbocharger Disassemble.
28. If the turbocharger is being reused, refer to Turbocharger Cleaning and Inspection.

Turbocharger replacement - Installation Procedure

1. Install the assembly parts to the turbocharger as necessary. Refer to Turbocharger Assemble.
2. Clean the sealing surfaces.

Fig. 203: Turbocharger Assembly And Gasket

3. Install a NEW turbocharger gasket.
4. Install the turbocharger assembly (1).

Fig. 204: Turbocharger Nuts

5. Install the 8 NEW turbocharger nuts (1).

Fig. 205: Turbocharger Nuts Tightening Sequence

CAUTION: Refer to Fastener Caution .

CAUTION: Refer to Torque-to-Yield Fastener Caution .

6. Tighten the 8 turbocharger nuts in a sequence as shown to 8 (71 lb in).
7. Repeat the tightening procedure to ensure a proper fastening of the turbocharger nuts.

NOTE: It is only necessary to move the wastegate actuator aside enough to access the manifold nuts.

8. Install the wastegate actuator and nuts and tighten to 7 (62 lb in).

Fig. 206: Turbocharger Oil Return Pipe Bolts

9. Install a NEW gasket and the 2 turbocharger oil return pipe bolts (1) and tighten to 8 (71 lb in).
10. Install the warm up three-way catalytic converter. Refer to Warm Up Three-Way Catalytic Converter Replacement (2H0, LUV) .

Fig. 207: Turbocharger Coolant Feed Pipe Components

11. Install the turbocharger coolant feed pipe to the engine block. Use the following procedure:

• Install a NEW seal ring (3) to the turbocharger coolant feed pipe hollow screw (4).
• Install the turbocharger coolant feed pipe hollow screw along with the seal ring to the turbocharger coolant feed pipe (2).
• Install a NEW seal ring (1) to the turbocharger coolant feed pipe hollow screw.
• Install the turbocharger coolant feed pipe hollow screw along with the turbocharger coolant feed pipe and the 2 seal rings to the engine.

Fig. 208: Ratchet Wrench And Holding Wrench

NOTE: The EN-49942 holding wrench should be installed in a perpendicular position as shown to ensure a proper installation position of the turbocharger coolant feed pipe.

12. Install the EN-49942 holding wrench (2) to the turbocharger coolant feed pipe. Guide a ratchet wrench (1) along with an extension through EN-49942 holding wrench to the turbocharger coolant feed pipe hollow screw.
13. Install the air conditioning compressor bracket then reposition and install the air conditioning compressor.

    Refer to Air Conditioning Compressor Bracket Replacement (LUJ, LUV) .

Fig. 209: Ratchet Wrench, Holding Wrench And Coolant Feed Pipe

NOTE: EN-49942 holding wrench (2) should be installed to the turbocharger coolant feed pipe as shown. The holding wrench should be installed to avoid twist of the turbocharger coolant feed pipe during the fastening procedure.

14. Tighten the turbocharger coolant feed pipe hollow screw with ratchet wrench and extension (1) to 30 (22 lb ft).
15. Install the charge air cooler inlet air hose to the turbocharger. Refer to Charge Air Cooler Inlet Air Hose Replacement .

Fig. 210: Turbocharger Oil Feed Pipe Components

16. Install the turbocharger coolant return pipe bolt (7) and tighten to 8 (71 lb in).
17. Install the turbocharger coolant return hose (6) to the oil cooler inlet pipe.
18. Install the turbocharger coolant return hose clamp.
19. Install the turbocharger oil feed pipe (2) to the oil cooler and the turbocharger.
20. Install the turbocharger oil feed pipe bolt (5).
21. Install the turbocharger oil feed pipe hollow screw (4) along with the 2 NEW seal rings (1) and (3) and tighten to 30 (22 lb ft).
22. Tighten the turbocharger oil feed pipe bolt to 10 (89 lb in).

Fig. 211: Turbocharger Wastegate Regulator Solenoid Valve Wiring Harness Connector And Retaining Clip

23. Connect the turbocharger wastegate regulator solenoid valve wiring harness connector (1) and clip in wiring harness to retainer clip (2).
24. Install the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement (LUV) .
25. Connect the positive crankcase ventilation pipe to the turbocharger.
26. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
27.  Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
28. Fill the cooling system. Refer to Cooling System Draining and Filling .
29. Use a scan tool to perform the Engine Control Module Setup for Component Replacement. Refer to Control Module References .

TURBOCHARGER OIL FEED PIPE REPLACEMENT

Removal Procedure

1. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement (LUV) .

Fig. 212: Turbocharger Oil Feed Pipe Components

3. Remove the turbocharger oil feed pipe bolt (5).
4. Remove the turbocharger oil feed pipe hollow screw (4) and the 2 seal rings (1) and (3).
5. Remove the turbocharger oil feed pipe (2) and the rubber seal ring.

Installation Procedure

1. Clean the sealing surfaces.

Fig. 213: Turbocharger Oil Feed Pipe Components

2. Install the turbocharger oil feed pipe (2) along with a NEW rubber seal ring.
3. Install the turbocharger oil feed pipe hollow screw (4) and 2 NEW seal rings (1) and (3).

CAUTION: Refer to Fastener Caution .

4. Install the turbocharger oil feed pipe bolt (5) and tighten to 8 (71 lb in).
5. Tighten the turbocharger oil feed pipe hollow screw to 20 (15 lb ft).
6. Install the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement (LUV) .
7. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection

TURBOCHARGER OIL RETURN PIPE REPLACEMENT

Removal procedure

1. Remove the front wheelhouse liner inner front extension.

Fig. 214: Turbocharger Oil Return Pipe Components

2. Remove the 2 turbocharger oil return pipe bolts (1).
3. Place a drain pan under the oil return pipe vehicle.
4. Release the turbocharger oil return pipe connector (4) and disconnect the turbocharger oil return pipe from the engine block.
5. Remove the turbocharger oil return pipe (2) and the gasket (3).

Installation Procedure

1. Clean the sealing surfaces.

Fig. 215: Turbocharger Oil Return Pipe Components

2. Install the turbocharger oil return pipe (2) in compound with a NEW gasket (3) and connect to the engine block.

CAUTION: Refer to Fastener Caution .

3. Install the 2 turbocharger oil return pipe bolts (1) and tighten to 8 (71 lb in).
4. Lower the vehicle and check for oil leaks.
5. Install the front wheelhouse liner inner front extension.

CAMSHAFT COVER REPLACEMENT

Fig. 216: Camshaft Cover, Fasteners And Oil Level Indicator

Camshaft Cover Replacement

INTAKE CAMSHAFT REPLACEMENT

Removal Procedure

1. Remove the camshaft intake and exhaust sprocket. Refer to Camshaft Intake and Exhaust Sprocket Replacement.

Fig. 217: Intake Camshaft Bearing Cap Bolts Removal Sequence

2. Remove the camshaft bearing cap bolts in sequence shown. Ensure to remove the bolts one turn at a time until there is no spring tension pushing on the camshaft.shing on the camshaft.

Fig. 218: Camshaft Bearing Caps And Bolts

NOTE: Mark the camshafts bearing caps and the camshaft upon removal to ensure installation is in the correct position.

3. Remove the camshaft bearing cap bolts (1).
4. Remove the camshaft bearing caps (2).
5. Remove the intake camshaft (3).

Installation Procedure

Fig. 219: Camshaft Bearing Caps And Bolts

NOTE: Ensure that the camshaft sealing rings are in place in the camshaft grooves. Camshaft sealing rings must be in place below the surface of the camshaft journal in order to avoid being pinched between the cylinder head and the camshaft caps.

1. Lubricate the camshaft and camshaft bearing caps with engine oil.
2. Install the intake camshaft (3).
3. Install the camshaft bearing caps (2).

CAUTION: Refer to Fastener Caution

4. Install the camshaft bearing cap bolts and tighten the bolts hand tight (1).

Fig. 220: Intake Camshaft Bearing Cap Bolts Tightening Sequence

5. Install and tighten the camshaft bearing cap bolts one turn at a time in sequence as shown to 8 N.m (71 lb in).
6. Install the camshaft intake and exhaust sprocket. Refer to Camshaft Intake and Exhaust Sprocket Replacement.

EXHAUST CAMSHAFT REPLACEMENT

Removal Procedure

1. Remove the camshaft intake and exhaust sprocket. Refer to Camshaft Intake and Exhaust Sprocket Replacement

Fig. 221: Camshaft Position Exciter Wheels And Camshaft Sprocket Bolts

2. Remove and DISCARD the camshaft sprocket bolts (2) and the camshaft position exciter wheels (1).
3. Allow the both camshaft sprockets with the timing chain to rest on the engine front cover.

Fig. 222: Exhaust Camshaft Bearing Cap Bolts Removal Sequence

4. Remove the camshaft bearing cap bolts in sequence shown. Ensure to remove the bolts one turn at a time until there is no spring tension pushing on the camshaft.

Fig. 223: Camshaft Bearing Caps And Bolts

NOTE: Mark the camshafts upon removal to ensure installation is in the correct position.

5. Remove the camshaft bearing cap bolts (1).
6. Remove the camshaft bearing caps (2).
7. Remove the exhaust camshaft (3).

Installation Procedure

Fig. 224: Camshaft Bearing Caps And Bolts

NOTE: Ensure that the camshaft sealing rings are in place in the camshaft grooves. Camshaft sealing rings must be in place below the surface of the camshaft journal in order to avoid being pinched between the cylinder head and the camshaft caps.

1. Lubricate camshaft and camshaft bearing caps with engine oil.
2. Install the exhaust camshaft (3).
3. Install the camshaft bearing caps (2).

CAUTION: Refer to Fastener Caution .

4. Install the camshaft bearing cap and hand tighten the bolts (1).

Fig. 225: Exhaust Camshaft Bearing Cap Bolts Tightening Sequence

5. Install and tighten the camshaft bearing cap bolts one turn at a time in sequence as shown 8 N.m (71 lb in).
6. Install the camshaft intake and exhaust sprocket. Refer to Camshaft Intake and Exhaust Sprocket Replacement.

VALVE STEM OIL SEAL AND VALVE SPRING REPLACEMENT

Special Tools

• EN-50717 Basic Kit, Spring and Wedge Replacer
• EN-840 Pliers / Remover
• EN-958 Installer
• EN-952 Fixing Pin

For equivalent regional tools, refer to Special Tools.

Removal Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the front wheelhouse liner . Refer to Front Wheelhouse Liner Replacement (Encore) , Front Wheelhouse Liner Replacement (Encore) .
3. Lower the vehicle.
4. Remove the hydraulic valve lash adjuster arms. Refer to Hydraulic Valve Lash Adjuster Arm Replacement.
5. Remove the spark plugs. Refer to Spark Plug Replacement .

NOTE: Wheels must contact the ground.

6. Shift to 5. gear (MT) or park position (AT) and apply the park brake.
7. Adjust the engine to TDC of cylinder 1 and fix the crankshaft. Refer to Camshaft Timing Chain Adjustment.

Fig. 226: Crankshaft Balancer Marking Position

8. Mark the crankshaft balancer 180º opposed to the cylinder 1 TDC marking.

Intake Valve Stem Oil Seal Removal Cylinder 1

Fig. 227: Rail Tightening Bolt And Supports

1. Prepare the 2 50717 supports (1) for the installation by tightening the support head in a centered position to the rail with the bolt (2).

Fig. 228: Intake Valve Stem Oil Seal Removal Components

2. Install the EN-6086-5 mounting shaft (3) along with the 2 EN-6086-6 supports (4) and the EN-6086-8 handle to the cylinder head.

NOTE: The demounting piece must point to the intake side.

3. Install the EN-6086-7 lever (2) along with the EN-6086-11 demounting piece (1) to the mounting shaft.
4. Position the mounting shaft centered above the spark plug bores and tighten the 4 fasteners (6).
5. Install the EN-6086-15 pneumatic adapter (5) to the spark plug screw bore of cylinder 1.
6. Apply air pressure to cylinder 1.

Fig. 229: Valve Spring Tension Lever And Demounting Piece

7. Remove the valve keys, valve spring retainers and the valve springs of the intake valves of cylinder 1, using the following procedure:

CAUTION: The demounting piece part of EN-6086 Basic Kit, Spring and Wedge Replacer must be applied parallel to the valve retainers in order to prevent damage to the tools or the valve train components. If demounting piece is not applied parallel it could cause damage to the valve stem keys or the valve retainers.

1. Apply tension to the valve springs, using the EN-6086-7 lever (1) and the EN-6086-11 demounting piece (2) until the valve keys are discharged from spring load and remove the valve keys.
2. Release tension from the valve springs and remove the valve spring retainers and the valve springs.

Fig. 230: Pliers And Intake Valve Stem Oil Seals

8. Remove the intake valve stem oil seals (2) of cylinder 1, using the EN-840 pliers (1).

Intake Valve Stem Oil Seal Installation Cylinder 1

Fig. 231: Intake Valve Stem Oil Seal Installation Tool

NOTE: Lubricate the NEW intake valve stem oil seals with clean engine oil.

1. Install the NEW intake valve stem oil seals of cylinder 1, using the EN-958 installer (1).

Fig. 232: Valve Key Installation Mounting Piece Components

2. Prepare the EN-6086-200-1 mounting piece for the valve key installation. The mounting piece must be assembled in the following order:

1. Support (6)
2. Bushing (5)
3. Spring (4)
4. EN-6086-200-10 plunger (3)
5.  Screw Connection (2)
6.  Lever Adapter (1)

Fig. 233: Valve Keys And Mounting Piece

3. Install the valve keys (1) to the mounting piece (2) and fix them with the bushing.

Fig. 234: Assembled Mounting Piece

4. Install the intake valve springs, the intake valve spring retainers and the intake valve keys, using the following procedure:

1. Replace the EN-6086-11 demounting piece with the assembled EN-6086-200-1 mounting piece (1).
2. Install the intake valve springs and the intake valve spring retainers to the cylinder head.

CAUTION: The demounting piece part of EN-6086 Basic Kit, Spring and Wedge Replacer must be applied parallel to the valve retainers in order to prevent damage to the tools or the valve train components. If demounting piece is not applied parallel it could cause damage to the valve stem keys or the valve retainers.

NOTE: The cone side of the valve keys must point to the valve stem.

3. Push down the mounting piece (1) using the lever (2) until the valve keys are hearable engaged.

Fig. 235: Intake Valve Keys

4. Inspect the intake valve keys (1) for proper seat.

Exhaust Valve Stem Oil Seal Removal Cylinder 1

Remove the exhaust valve stem oil seals of cylinder 1:

1. Transfer the EN-6086-7 lever to the exhaust side of cylinder 1.
2. Replace the EN-6086-200-1 mounting piece with the EN-6086-11 demounting piece.
3. Remove the exhaust valve keys, exhaust valve spring retainers, exhaust valve springs and the exhaust valve stem oil seals as described above.

Exhaust Valve Stem Oil Seal Installation Cylinder 1

1. Replace the EN-6086-11 demounting piece with the assembled EN-6086-200-1 mounting piece (1).
2. Install the exhaust valve keys, exhaust valve spring retainers, exhaust valve springs and the exhaust valve stem oil seals of cylinder 1 as described above.

Intake Valve Stem Oil Seal Removal Cylinder 4

1. Release the air pressure from cylinder 1.
2. Transfer the EN-6086-15 pneumatic adapter from cylinder 1 to the spark plug bore of cylinder 4.
3. Apply air pressure to cylinder 4.
4. Transfer the EN-6086-7 lever to the intake side of cylinder 4.
5. Replace the EN-6086-200-1 mounting piece with the EN-6086-11 demounting piece.
6. Remove the intake valve keys, intake valve spring retainers, intake valve springs and the intake valve stem oil seals of cylinder 4 as described above.

Intake Valve Stem Oil Seal Installation Cylinder 4

1. Replace the EN-6086-11 demounting piece with the assembled EN-6086-200-1 mounting piece.
2. Install the intake valve keys, intake valve spring retainers, intake valve springs and the intake valve stem oil seals of cylinder 4 as described above.

Exhaust Valve Stem Oil Seal Removal And Installation Cylinder 4

Replace the exhaust valve keys, exhaust valve spring retainers, exhaust valve springs and the exhaust valve stem oil seals of cylinder 4 as described above.

Intake Valve Stem Oil Seal Removal Cylinder 2

1. Release the air pressure from cylinder 4.
2. Raise the vehicle.
3. Remove the EN-952 fixing pin from the crankshaft.

Fig. 236: Crankshaft Balancer Markings

4. Rotate the crankshaft balancer in engine rotation direction until the 180º opposite marking (2) aligns with the marking (1) on the engine front cover.
5. Lower the vehicle.

NOTE: Wheels must contact the ground.

6. Block the engine by shifting the 5. gear (MT) or park position (AT) and applying the park brake.
7. Transfer the EN-6086-15 pneumatic adapter from cylinder 4 to the spark plug bore of cylinder 2.
8. Apply air pressure to cylinder 2.
9. Transfer the EN-6086-7 lever to the intake side of cylinder 2.
10. Replace the EN-6086-200-1 mounting piece with the EN-6086-11 demounting piece.
11.  Remove the intake valve keys, intake valve spring retainers, intake valve springs and the intake valve stem oil seals of cylinder 2 as described above.

Intake Valve Stem Oil Seal Installation Cylinder 2

1. Transfer the EN-6086-7 lever to the exhaust side of cylinder 2.
2. Replace the EN-6086-11 demounting piece with the assembled EN-6086-200-1 mounting piece (1).
3. Install the intake valve keys, intake valve spring retainers, intake valve springs and the intake valve stem oil seals of cylinder 2 as described above.

Exhaust Valve Stem Oil Seal Removal And Installation Cylinder 2

Replace the exhaust valve keys, exhaust valve spring retainers, exhaust valve springs and the exhaust valve stem oil seals of cylinder 2 as described above.

Intake Valve Stem Oil Seal Removal Cylinder 3

1. Release the air pressure from cylinder 2.
2. Transfer the EN-6086-15 pneumatic adapter from cylinder 2 to the spark plug bore of cylinder 3.
3. Apply air pressure to cylinder 3.
4. Transfer the EN-6086-7 lever to the intake side of cylinder 3.
5. Replace the EN-6086-200-1 mounting piece with the EN-6086-11 demounting piece.
6. Remove the intake valve keys, intake valve spring retainers, intake valve springs and the intake valve stem oil seals of cylinder 3 as described above.

Intake Valve Stem Oil Seal Installation Cylinder 3

1. Transfer the EN-6086-7 lever to the exhaust side of cylinder 3.
2. Replace the EN-6086-11 demounting piece with the assembled EN-6086-200-1 mounting piece.
3. Install the intake valve keys, intake valve spring retainers, intake valve springs and the intake valve stem oil seals of cylinder 3 as described above.

Exhaust Valve Stem Oil Seal Removal And Installation Cylinder 3

Replace the exhaust valve keys, exhaust valve spring retainers, exhaust valve springs and the exhaust valve stem oil seals of cylinder 3 as described above.

Installation Procedure

1. Release air pressure from cylinder 3.
2. Remove the EN-6086-15 pneumatic adapter.
3. Remove all parts of EN-50716 spring and wedge replacer.
4. Shift to neutral gear and release the park brake.
5. Adjust the engine to TDC of cylinder 1 and fix the crankshaft with EN-952 fixing pin.
6. Install the spark plugs. Refer to Spark Plug Replacement .
7. Install the hydraulic valve lash adjuster arms. Refer to Hydraulic Valve Lash Adjuster Arm Replacement.
8. Raise the vehicle.
9. Remove the EN-952 fixing pin and install the crankshaft bearing cap tie plate hole plug. Refer to Camshaft Timing Chain Adjustment.
10. Install the front wheelhouse liner . Refer to Front Wheelhouse Liner Replacement (Encore) , Front Wheelhouse Liner Replacement (Encore) .
11. Lower the vehicle.

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