Turbocharger: Service and Repair
INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC]WARNING:
- A hot engine and intake air system can cause severe burns. Turn oft the engine and wait until they are cool before removing the intake air system.
- Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
- Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure". (See BEFORE REPAIR PROCEDURE[L3 WITH TC].)
1. Disconnect the negative battery cable.
2. Remove the charge air cooler duct.
3. Remove the battery and battery tray.
4. Remove the under cover.
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. Complete the "AFTER REPAIR PROCEDURE". (See AFTER REPAIR PROCEDURE[L3 WITH TC].) After Repair Procedure
Resonance Chamber Removal Note
1. Remove the mudguard (LF).
2. Remove the resonance chamber.
Air Hose Removal Note
1. Disconnect the variable swirl shutter valve switch connector.
2. Disconnect the fuel injector harness connector.
3. Disconnect the ventilation hose connected to the air hose.
4. Remove the air hose.
Air Duct Removal Note
1. Disconnect the wastegate control solenoid valve connector.
2. Disconnect the purge solenoid valve connector.
3. Disconnect the EGR valve connector.
4. ATF gage pipe out of the way.
5. Remove the air duct.
Throttle Body Removal Note
1. Disconnect the throttle body connector.
2. Drain the engine coolant before removing the water hose. (See ENGINE COOLANT REPLACEMENT[L3 WITH TC].)
3. Remove the throttle body.
Intake Manifold Removal Note
1. Remove the fuel delivery pipe cover.
2. Disconnect the quick connector connected to the intake manifold.
3. Remove the EGR pipe.
4. Disconnect the variable swirl solenoid valve connector.
5. Disconnect the OCV connector.
6. Disconnect the PSP switch connector.
7. Remove the oil level gauge pipe.
8. Remove the splash shield (RF).
9. Remove the drive belt.
10. Set the power steering oil pump out of the way.
11. Disconnect the fuel pressure sensor connector.
12. Disconnect the vacuum hose connected between the intake manifold and the master cylinder from the intake manifold.
13. Disconnect the MAP sensor connector.
14. Remove the intake manifold installation bolts.
15. Disconnect the evaporative hose connected between the intake manifold and the PCV valve from the intake manifold.
16. Remove the intake manifold.
Turbocharger Removal Note
1. Remove the middle pipe.
2. Disconnect the rear HO25 connector.
3. Remove the front pipe.
CAUTION: When removing the cowl grille, a part or tool may hit the edge of the windshield and could damage it. Protect the windshield by covering it with a clean rag to prevent damage to the windshield.
4. Remove the cowl grille.
5. Remove the windshield wiper motor.
6. Remove the cowl panel.
7. Remove the insulator (Exhaust manifold upper side).
8. Set the generator out of the way.
9. Remove the insulator (Exhaust manifold lower side).
10. Disconnect the front H025 connector.
11. Remove the insulator (WU-TWC top side).
12. Remove the vacuum hose (Brake master back side).
13. Remove the front H025.
14. Remove the WU-TWC.
15. Remove the oil pipes.
16. Remove the turbocharger.
Turbocharger Installation Note
1. install the turbocharger.
Tightening torque
38 - 51 N.m (3.9 - 5.2 kgf.m, 29 - 37 ft.lbf)
2. Install the WU-TWC.
3. Install the front HO2S.
4. Tight the oil pipe installation bolt while the stopper of the oil pipe is faced to the turbocharger.
5. Install the oil pipes and, insert the oil hose until it reaches the stopper.
Wastegate Control Solenoid Valve Installation Note
1. Install the wastegate control solenoid valve.
Tightening torque
7.8 - 10.8 N.m (8 - 110 kgf.cm, 7O - 95 in.lbf)
2. Install the hose as shown in the figure.
Throttle Body Installation Note
1. Tighten the throttle body installation bolts in the order shown in the figure.
Tightening torque
8 - 11.5 N.m (82 - 117 kgf.cm, 71 - 101 in.lbf)
Air Cleaner Case Installation Note
CAUTION:
- Before assembling the air cleaner, verify that the rubber mounts have not fallen oft from the air cleaner bracket (3 locations).
- Always install the air cleaner case using the following procedure.
NOTE: When inserting the rubber mounts into the air cleaner case, soapy water can be applied.
1. Verify that the rubber mounts are set in the air cleaner bracket (3 locations).
2. Install the projections on the frame side (2 locations).
3. Verify that the projections on the frame side are installed securely.
4. Install the projection on the engine side (remaining location).
5. Verify that the projection on the engine side installed securely.