Turbocharger: Service and Repair

Turbo System Component Replacement:

CAUTION: Use these precautions when handling and replacing turbocharger:
^ Do not hold actuator rod or hose when carrying turbocharger.
^ Do not damage actuator and rod.
^ Cover turbo compressor inlet/outlet, turbine exhaust inlet/outlet, and oil passage to prevent dirt or other material from entering.
^ Set turbocharger down with turbine shaft horizontal.
^ Use specified new studs on installation.

COMPONENTS
1. Negative battery cable
2. Under cover
3. Bracket
4. Main converter assembly
5. Insulator
6. Oxygen sensor
7. Front converter
8. Fresh air duct
9. Air hoses
10. Air cleaner
11. Accelerator cable
12. Pressure chamber
13. Air pipe
14. Drive belt
15. Air pump
16. Air hose
17. Air pipe
18. Charge control valve assembly
19. Air intake pipe (secondary)
20. Air intake pipe (primary)
21. Water hose
22. Oil return pipes
23. Oil pipe
24. Water hose
25. Turbocharger
26. Actuator (turbo control)

REMOVAL/INSTALLATION

1. Disconnect negative battery cable.
2. Raise vehicle and drain coolant.
3. Remove components in order shown.
4. Install in reverse order, referring to Installation Note.

Installation Note

Turbo Control Actuator:

1. Verify that paint mark on actuator rod is aligned with actuator bracket end.
2. If mark is not aligned, adjust actuator rod length.

Turbo Mounting Studs:

3. Check stud bolt torque before turbocharger installation:

A: 12 - 17 ft lb (16 - 24 Nm)
B: 5.8 - 8.7 ft lb (8 - 12 Nm)