Turbocharger: Service and Repair

Turbocharger And Related Components:

1. Disconnect battery ground cable.





2. Remove intake air boot between intercooler and throttle body.





3. Remove intake air boot from air flow sensor housing and disconnect hose to turbocharger.





4. Unclip air cleaner box cover.





5. Remove oxygen sensor and emission test tube.

Disconnecting Exhaust From Turbocharger:

6. Remove cover plate and disconnect exhaust pipe from turbocharger.





7. Disconnect corrugated exhaust tube from wastegate.

Exhaust Bracket And Junction:

8. Remove exhaust pipe from manifold to front muffler.





9. Remove air cooling hose to alternator and right engine mount.





10. Remove intake air hose from between turbocharger and intercooler.





11. Disconnect lower coolant line and oil return line from turbocharger.





12. Remove alternator.





13. Disconnect remaining coolant and oil lines from turbocharger and remove turbocharger.
14. Plug engine oil and coolant lines and cover fluid connection ports on the turbocharger to keep dirt and other contamination out.

Install in reverse order.

INSTALLATION NOTE:
Fill turbocharger bearing housing with clean engine oil through oil feed connection and spin turbo by hand to make sure the bearings are well lubricated prior to installation. Allow engine to idle for at least one minute before reving an engine with a new turbocharger installed.