Turbocharger: Service and Repair

Turbocharging System:

Exhaust Manifold/Turbocharger Assembly:

1. Be sure the engine and exhaust system are cool enough to touch and drain the engine coolant.

2. Remove heat shielding from exhaust manifold and turbocharger.

3. Disconnect air hoses, coolant hoses, and oil lines from turbocharger.

4. Disconnect EGR pipe and remove oxygen sensor from exhaust manifold.

5. Disconnect front exhaust pipe from turbocharger exhaust outlet and pull it away. It may also be necessary to disconnect the front pipe from the catalytic converter and remove it completely.

6. Remove lower bracket from turbocharger.

7. Remove turbocharger and exhaust manifold from the engine as an assembly, then disassemble the turbo from the exhaust manifold.

NOTE: Cover inlets and outlets to prevent dirt or other contaminants from getting into turbo housing or bearing assembly.

Assemble in the reverse order. Tighten bolts to the following torque specifications.

MANIFOLD TO CYL. HEAD [1] ... 25 - 36 ft lbs/34 - 49 Nm

TURBOCHARGER TO MANIFOLD ... 20 - 29 ft lbs/27 - 39 Nm

TURBOCHARGER TO JOINT PIPE ... 27 - 46 ft lbs/37 - 63 Nm

[1] Tighten in three steps.