Turbocharger: Service and Repair
REMOVALTurbocharging 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.
CAUTION: Observe the following precautions when servicing the turbocharger.
a. Do not drop the turbocharger.
b. Don't use the wastegate actuator rod for carrying the unit.
c. Cover inlets and outlets to prevent dirt or other contaminants from getting into turbo housing or bearing assembly.
d. Do not bend wastegate actuator rod or actuator bracket.
e. Store turbocharger with impeller/compressor shaft in horizontal position.
DISASSEMBLY
Turbocharger Assembly - Serviceable Parts:
1. Remove exhaust joint pipe from turbocharger.
Aligning Turbine Housing And Compressor Housing W/Bearing Assembly:
2. Set turbocharger assembly on a flat surface and mark the relative positions of the turbine housing and bearing hub oil outlet pipe, for reference during re-assembly (mark "A", see illustration).
3. Note and mark the position of the compressor housing relative to the bearing hub assembly, for reference during re-assembly (mark "B", see illustration).
4. Remove the wastegate actuator and compressor housing retainer plates, and separate compressor housing from bearing hub assembly.
5. Remove turbine housing retainer plates and separate turbine housing from bearing hub assembly.
ASSEMBLY NOTES
Correct Sealant Application:
1. Clean all sealer from compressor and turbine housings and apply a fresh, thin bead of appropriate sealer, as shown in illustration.
2. Carefully align bearing housing with turbine and compressor housings according to marks previously made.
Correct Positioning Of Turbine Retainer Plates:
3. Install turbine housing retainer plates as shown in illustration, to prevent heat distortion. Torque bolts to the specification listed below.
20 - 21 ft.lbs (27 - 29 Nm)
Installing Compressor Retainer Plates:
4. Install compressor housing retainer plates with rounded edges facing compressor housing, as shown in illustration. Torque bolts to the specificaton listed below.
37 - 46 in.lbs (4.2 - 5.2 Nm)
INSTALLATION NOTES
1. Install in the reverse order of removal.
2. Prior to installation, add approx. 1 oz. (25 - 30cc) of clean engine oil to the bearing hub assembly oil inlet.
3. Replace manifold to cyl. head nuts and turbo to manifold nuts. Tighten fasteners to the following torque specifications.
MANIFOLD TO CYL. HEAD [1] ........ 25 - 34 ft.lbs (34 - 46 Nm)
TURBOCHARGER TO MANIFOLD ..........23 - 30 ft.lbs (31 - 41 Nm)
TURBOCHARGER TO JOINT PIPE ....... 27 - 46 ft.lbs (37 - 63 Nm)
WATER PIPE TO TURBOCHARGER ....... 25 - 28 ft.lbs (34 - 38 Nm)
OIL INLET PIPE TO ENGINE BLOCK ... 23 - 34 ft.lbs (31 - 46 Nm)
[1] Tighten in three steps.