Turbocharger: Service and Repair

TURBOCHARGER REMOVAL/INSTALLATION [BP WITH TC]

WARNING:
- A hot engine and intake air system can cause severe burns. Turn off the engine and wait until all components are cool before removing the intake air system.
- Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and cause serious injury or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure". (See BEFORE SERVICE PRECAUTION [BP, BP WITH TC].)

1. Disconnect the negative battery cable.
2. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT.)
3. Remove the under cover.
4. Disconnect the MAF sensor connector.
5. Disconnect the IAT sensor No.1 connector.
6. Remove the air cleaner cover together with the MAF sensor and the IAT sensor No.1. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [BP WITH TC].)
7. Remove the air cleaner case. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [BP WITH TC].)
8. Remove the air hose No.3 and air pipe No.2. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [BP WITH TC].)
9. Remove the air pipe No.1 together with the air bypass valve. (See INTAKE-AIR SYSTEM REMOVAL' INSTALLATION [BP WITH TC].)
10. Remove the exhaust manifold insulator. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [BP WITH TC].)
11. Remove the turbocharger insulator. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [BP WITH TC].)
12. Remove the joint pipe insulator No.1. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [BP WITH TC].)
13. Remove the dipstick. (See OIL PAN REMOVAL/INSTALLATION [BP WITH TC].)
14. Remove the H02S (front). (See EXHAUST SYSTEM REMOVAL/INSTALLATION [BP WITH TC].)
15. Remove the joint pipe insulator No.2. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [BP WITH TC].)
16. Remove the H02S (rear). (See EXHAUST SYSTEM REMOVAL/INSTALLATION [BP WITH TC].)
17. Remove the TWC. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [BP WITH TC].)
18. Remove the joint pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [BP WITH TC].)
19. Remove the oil pipe (oil in). (See EXHAUST SYSTEM REMOVAL/INSTALLATION [BP WITH TC].)
20. Remove the oil pipe (oil out) nuts. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [BP WITH TC].)
21. Remove the engine coolant pipe (engine coolant out). (See EXHAUST SYSTEM REMOVAL/ INSTALLATION [BP WITH TC].)
22. Remove the EGR pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [BP WITH TC1.)
23. Remove the turbocharger bracket. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [BP WITH TC].)
24. Remove the turbocharger together with the exhaust manifold. (See EXHAUST SYSTEM REMOVAL/ INSTALLATION [BP WITH TC].)
25. Install in the reverse of removal.
26. Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION [BP, BP WITH TC].)