Turbocharger: Service and Repair

1. When replacing turbocharger, always check engine oil level and quality, as well as the oil pipe leading to turbocharger, and the oil return pipe, replacing as necessary.
2. When removing, installing or handling turbocharger, note the following:
a. Do not drop turbocharger.
b. Do not bend actuator mounting or rod.
c. Cover intake, exhaust and oil passages to prevent dirt or other particles from entering.
d. Do not use actuator rod to carry turbocharger.
e. Place turbocharger with turbine shaft horizontal.
3. When installing turbocharger, perform the following:
a. Remove all gaskets and sealant.
b. Use new gaskets.
c. Add 1.5 cubic inches of oil in the oil passage of turbocharger.
4. After replacing turbocharger, perform the following:
a. Disconnect connector from negative terminal of ignition coil.
b. Crank engine for 20 seconds.
c. Reconnect connector.
d. Start engine and run at idle for 30 seconds.
e. Stop engine and disconnect negative battery cable and depress brake pedal for 5 seconds to erase malfunction code.
5. Disconnect battery ground cable.
6. Cool engine and drain coolant.
7. Remove air hoses and air bypass valve.
8. Remove insulators.
9. Remove oil pipe and oil return hose from turbocharger.
10. Disconnect water hoses from water pipe.
11. Remove EGR pipe from exhaust manifold.
12. Remove oxygen sensor, then disconnect front exhaust pipe.
13. Remove turbocharger and exhaust manifold as an assembly.
14. Separate turbocharger from exhaust manifold.
15. Reverse procedure to install.