Turbocharger: Service and Repair

Crankcase Ventilation Hose And Clamp:

1. Disconnect air mass sensor electrical connector and, remove crankcase ventilation hose from inlet side of turbocharger remove air duct between air mass sensor and turbocharger.

Air Cleaner Upper Section Fastener Location:

2. Remove mounting screw for air cleaner upper section, release spring clips and remove air cleaner upper section.

Air Cleaner Fasteners:

3. Remove air cleaner lower section.

Air Duct (Intercooler To Intake Pipe):

4. Remove air duct from between intercooler and intake tube to throttle body.

Removing Wastegate:

5. Remove boost pressure line (banjo fiting), unbolt flexible exhaust pipe section and remove wastegate from exhaust manifold.

Boost Pressure Line And Wastegate Frequency Valve:

6. Remove hose from between wastegate frequency valve and turbocharger.

Exhaust Pipe To Turbocharger Nuts:

7. Remove turbocharger to exhaust pipe mounting nuts.

NOTE: The nuts are 15mm and may be difficult to reach with a tool.

Coolant Supply Line:

Coolant And Oil Supply Lines:

8. Remove turbocharger coolant supply and oil supply lines from turbocharger.


NOTE: Plug all coolant and oil hose connections to prevent dirt and other contamination from getting in.

Hose Clamp (Boost Pressure Hose To Intercooler):

9. Remove boost pressure hose from between turbocharger and intercooler.

Oil Return To Crankcase:

10. Remove oil return line from crankcase.

Heat Shield Fasteners:

11. Remove heat shield (below turbocharger).

Turbo To Manifold Bolts:

12. Remove turbocharger from exhaust manifold.

Install in reverse order.

INSTALLATION NOTES:

1. Lubricated turbocharger bearings by filling bearing hub section with clean engine oil through oil supply connection and spin turbo by hand prior to installation.
2. When first starting engine after installing turbo, allow engine to run at idle for several minutes before reving it up. This is to ensure adequate oil supply to engine and turbocharger bearings.