Turbocharger: Service and Repair

TURBOCHARGER

REMOVAL
1. Disconnect the battery negative cables.
2. Raise vehicle on hoist.
3. Disconnect the exhaust pipe from the turbocharger elbow.
4. Remove the bolts from the turbocharger oil drain tube.
5. Lower vehicle.






6. Disconnect the turbocharger air inlet hose.






7. Disconnect the turbocharger oil supply line from the turbocharger.






8. Disconnect the charge air cooler inlet pipe from the turbocharger compressor outlet.
9. Remove the turbocharger and gasket from the exhaust manifold.
10. If the turbocharger is not to be installed immediately, cover the opening to prevent material from entering into the manifold.
11. If replacing the turbocharger, transfer the turbocharger oil supply fitting to the new assembly. Tighten fitting to 36 Nm (27 ft. lbs.).
12. Clean and inspect the sealing surface.

CAUTION: The turbocharger is only serviced as an assembly. Do not attempt to repair the turbocharger as turbocharger and/or engine damage can result.


INSTALLATION

1. Install the turbocharger. Apply anti-seize to the studs and then tighten the turbocharger mounting nuts to 43 Nm (32 ft. lbs.) torque.
2. Pre-lube the turbocharger. Pour 50 to 60cc (2 to 3 oz) clean engine oil in the oil supply line fitting. Carefully rotate the turbocharger impeller by hand to distribute the oil thoroughly.
3. Install and tighten the oil supply line to 24 Nm (18 ft.lbs.)torque.
4. Position the charge air cooler inlet pipe to the turbocharger. With the clamp in position, tighten the clamp nut to 11 Nm (95 in.lbs.) torque.
5. Position the air inlet hose to the turbocharger. Tighten the clamp to 11 Nm (95 inch lbs.) torque.
6. Raise vehicle on hoist.






7. Useing a new gasket, install the oil drain tube to the turbocharger. tighten the drain tube bolts to 24 Nm (18 ft.lbs.) torque.
8. Tighten the oil drain tube clamps to 8 Nm (71 in.lbs.).
9. Connect the exhaust pipe to the turbocharger and tighten the bolts to 11.3 Nm (100 inch lbs.) torque.
10. Lower the vehicle.
11. Connect the battery negative cables.
12. Start the engine to check for leaks.