Turbocharger: Service and Repair

When replacing turbocharger, always check engine oil level and quality, oil pipe leading to turbocharger and the oil return pipe, replacing as necessary.
1. Cool the engine.
2. Drain engine coolant.
3. Align No. 1 cylinder at top dead center.
4. Remove distributor and the high tension leads.
5. Remove air funnel and air hose.
6. Remove secondary air pipe.
7. Remove lower insulator cover.
8. Remove secondary air pipe and nipple.
9. Remove oil pipe from turbocharger.
10. Remove upper insulator cover.
11. Remove EGR pipe.
12. Remove water hoses.
13. Remove O2 sensor.
14. Remove front pipe from front catalytic converter.
15. Loosen attaching bolts, under turbocharger, securing turbocharger to bracket.
16. Remove exhaust manifold, turbocharger, and front catalytic converter as an assembly. Do not drop turbocharger. Do not bend actuator mounting and rod. Cover intake, exhaust and oil passages to prevent entry of foreign matter.
17. Remove bracket.
18. Disassemble exhaust manifold, turbocharger and front catalytic converter.
19. Reverse procedure to install, noting the following:
a. Remove all gaskets and sealant.
b. Install new gaskets.
c. Supply 25cc of oil to oil passage of turbocharger.
d. Torque exhaust manifold to turbocharger attaching bolts to 23-32 ft. lbs.
e. Upon completion of installation, disconnect connector from negative terminal of ignition coil and crank engine for 20 seconds, then start engine and run at idle for 20 seconds.