Turbocharger: Service and Repair

Before performing turbocharger service, note the following general cautions:
1. Clean area around turbocharger assembly with a non-caustic solution before service. Cover opening of engine assembly connections to prevent entry of foreign material.
2. During removal of turbocharger assembly, do not bend, nick or in any way damage compressor or turbine wheel blades. Any damage may result in rotating assembly imbalance, and failure of the center housing rotating assembly and the compressor and/or turbine housing.
3. Before disconnecting center housing rotating assembly from either compressor housing or turbine housing, mark location of components for assembly in original position. Do not use a sharp tool to mark positions of turbocharger components. Use a piece of chalk.

WASTEGATE ACTUATOR, REPLACE

1. Disconnect air induction tube from intake manifold and turbocharger.
2. Remove actuator rod to wastegate clip, then disconnect vacuum hose from wastegate.
3. Remove screws retaining actuator to turbocharger.
4. Remove actuator assembly.
5. Reverse procedure to install.

Fig. 6 Air Induction Tube Assembly:

Fig. 7 Turbocharger Assembly:

Fig. 8 Exhaust Manifold & Gasket Assembly:

TURBOCHARGER, REPLACE

1. Disconnect battery ground cable.
2. Raise and support vehicle.
3. Remove lower fan retaining screw, then disconnect exhaust pipe from exhaust manifold.
4. Remove rear A/C support bracket bolt, then loosen remaining bolts.
5. Remove turbocharger support bracket to engine bolt and oil drain hose from turbocharger.
6. Lower vehicle.
7. Disconnect coolant recovery line from engine and position aside.
8. Disconnect air induction tube from intake manifold and turbocharger. Fig. 6.
9. Remove coolant fan from vehicle.
10. Remove oxygen sensor from exhaust manifold.
11. Disconnect oil feed pipe from engine.
12. Remove air intake duct from turbocharger, then disconnect vacuum hose from actuator.
13. Remove exhaust manifold retaining nuts, exhaust manifold and turbocharger assembly from engine. Figs. 7 and 8.
14. Reverse procedure to install.