Buick Regal: Turbocharger Removal (1ST Design Tamper-Proof PCV System)

1.

NOTE: In the event that a bolt breaks upon removal of components, perform an extraction of the broken bolt.

Remove the turbocharger heat shield bolts (1, 3).

2. Remove the turbocharger heat shield (2).

3.

Remove the turbocharger wastegate actuator arm retainer (3).

4. Remove the turbocharger wastegate actuator bolts (1) and actuator (2).

5.

Remove the camshaft cover heat shield bolt (1) that retains the turbocharger coolant return pipe (2) at the camshaft cover.

6. Disconnect the turbocharger coolant return pipe from the air bleed hose.

7. Remove the turbocharger coolant return pipe bolt (3).

8. Remove the turbocharger coolant return pipe (2) and washers (4, 5). Discard the washers.

9.

Remove the turbocharger coolant feed pipe bolts (1, 3).

10. Disconnect the turbocharger coolant feed pipe hose from the engine oil cooler.

11. Remove the turbocharger coolant feed pipe gasket (4) and discard.

12. Remove the turbocharger coolant feed pipe (5) and washers (2). Discard the washers.

13.

Disconnect the turbocharger wastegate regulator solenoid valve hoses from the turbocharger.

14. Remove the turbocharger wastegate regulator solenoid valve bracket bolt (2).

15. Remove the turbocharger wastegate regulator solenoid valve (1).

16.

Remove the turbocharger bypass valve solenoid bolts (1).

17. Remove the turbocharger bypass valve solenoid (2).

18.

NOTE: Do not disturb the joint between the PCV hose and PCV hose fitting at the turbocharger. This is a permanent connection.

Remove the PCV hose fitting bolt (2). Disconnect the PCV hose fitting (1) with the PCV hose attached from the turbocharger.

19.

Remove the turbocharger nuts (2) and discard.

20. Remove the turbocharger oil feed and return pipe bolts (6) at the engine block.

21. Remove the turbocharger (1) with the oil return pipe and oil feed pipe attached.

22. Remove the turbocharger oil feed and oil return pipe gaskets (4, 5) and discard.

23. Remove the turbocharger gasket (3) and discard.

24.

Remove the turbocharger oil feed pipe bolt (1) from the turbocharger.

25. Remove the turbocharger oil feed pipe (2) and washers (3). Discard the washers.

26. Remove the turbocharger oil return pipe bolts (6).

27. Remove the turbocharger oil return pipe (5).

28. Remove and discard the turbocharger oil return pipe gasket (4).

29. Clean and inspect the turbocharger and components. Refer to Camshaft Cover and Compressor Air Intake Turbocharger Cleaning and Inspection.

EXHAUST MANIFOLD REMOVAL

1.

NOTE: In the event that a bolt breaks upon removal of components, perform an extraction of the broken bolt.

Remove the exhaust manifold heat shield bolts (2).

2. Remove the exhaust manifold heat shield (1).

3.

Remove the exhaust manifold brace nuts (1) and discard.

4. Remove the exhaust manifold brace bolts (3).

5. Remove the exhaust manifold brace (2).

6.

Remove and discard the exhaust manifold to cylinder head bolts (3).

7. Remove the exhaust manifold (1).

8. Remove and discard the exhaust manifold gasket (2).

9. Clean all of the sealing surfaces.

FUEL RAIL AND INJECTORS REMOVAL

Special Tools

EN-49248 Fuel Rail Assembly Remover

For equivalent regional tools, refer to Special Tools

1.

WARNING: The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.

Remove the fuel injection fuel rail noise shield (1).

2.

Disconnect the electrical harness from the fuel rail harness connection.

NOTE: Fuel rail bolts are captured in the fuel rail assembly

• Ensure the bolt is completely loosened, and the threads are no longer engaged.
• Use a suitable tool to apply enough force to pull the bolt straight out of the fuel rail.

3. Remove the fuel rail assembly retaining bolts.

NOTE: Use care to avoid contact with the fuel rail harness during special tool installation and fuel rail removal.

4. Install EN-49248 studs (1) into the 2 outermost fuel rail assembly retaining bolt locations. Tighten the studs to 22 N.m (16 lb ft).

5. Install EN-49248 remover (2) onto each stud, and engage the hooks to the fuel rail. Install the nuts (3) retaining the remover onto the studs and tighten until snug.

6.

CAUTION:

• Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips.

  Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components.

• Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and passages.

NOTE: EN-49248 will assist in the proper removal of the fuel rail assembly. Ensure that the following conditions are met:

• Turn the handles simultaneously in order to pull the fuel rail straight out along the fuel injector axis.
• DO NOT twist when pulling out on the fuel rail and injector assembly.

Using EN-49248 remover, remove the fuel rail assembly.

CAMSHAFT COVER REMOVAL (1ST DESIGN TAMPER-PROOF PCV SYSTEM)

1.

Remove the engine coolant air bleed pipe bolt (1).

2. Remove the engine coolant air bleed pipe (2), hose (3), and O-ring (4). Inspect O-ring and discard if necessary.

3.

Remove the oil level indicator (3). Inspect and replace the oil indicator O-ring seals (4), if necessary.

4. Remove the camshaft cover heat shield (2) and bolts (1).

5.

Remove the rear lift bracket (1) and bolts (2).

6.

Remove the front lift bracket (2) and bolts (1).

7.

Remove the ignition coils (2) and bolts (1).

8.

Remove the camshaft position actuator solenoid valves (2) and bolts (1).

9.

Remove the vacuum assembly (2) and bolts (1).

10. Remove the vacuum assembly gasket (3) and discard.

11.

Remove the camshaft cover bolts (1, 3) and camshaft cover (2).

NOTE: Ensure all camshaft cover gaskets, including the inner gaskets, are removed and discarded.

12. Remove and discard the camshaft cover gaskets and camshaft cover inner gaskets (4).

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