Turbocharger: Service and Repair

Turbocharger Assembly:

1. Make sure engine and exhaust system are cool enough to touch.
2. Drain engine coolant.
3. Disconnect air pump hoses and remove air pump.
4. Remove air bypass valve, air funnel, and air hose between air cleaner and turbocharger.
5. Remove air control valve and split air pipe from lower section of intake manifold.
6. Remove water hose and water pipe.
7. Remove oil pipes.
8. Remove turbocharger and front catalytic converter insulator covers.
9. Disconnect turbocharger from front catalytic converter flange.
10. Disconnect turbocharger from air hose to intercooler.
11. Remove turbocharger from exhaust manifold.
12. Plug oil pipe openings to the engine and on the turbocharger to prevent dirt or other contamination from getting into the engine oiling system or turbocharger bearings.
13. After inspection, cover air and exhaust inlets and outlets on the turbocharger to keep dirt out.

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. Tighten bolts to the following torque specifications.

FRONT CATALYTIC CONVERTER TO TURBOCHARGER
33 - 40 ft.lbs (44 - 54 Nm)

TURBOCHARGER TO EXHAUST MANIFOLD
33 - 40 ft.lbs (44 - 54 Nm)

EXHAUST MANIFOLD TO ENGINE HOUSING
23 - 34 ft.lbs (31 - 46 Nm)

OIL PIPE TO ENGINE HOUSING
14 - 19 ft.lbs (19 - 25 Nm)