Turbocharger: Service and Repair

REMOVAL

1. Disconnect negative battery cable.
2. Drain cooling system.
3. Remove throttle body air intake tube.
4. Disconnect intercooler hose from turbocharger assembly and position both intercooler hoses aside.
5. Remove oxygen sensor connector from its retaining clip and disconnect sensor.
6. Remove three bolts retaining lower heat shield to turbocharger and remove lower heat shield.
7. Remove two bolts retaining upper heat shield to exhaust manifold and remove upper heat shield.

Exhaust Manifold Heat Shield:

NOTE: Feed oxygen sensor wire and guide through upper heat shield.

Lower Heat Shields:

8. Remove three bolts retaining side heat shield to turbocharger and remove side heat shield.

NOTE: It is necessary to remove power steering pump and mounting bracket to access lower left exhaust manifold retaining nut and to remove exhaust manifold from studs.

9. Remove power steering belt.
10. Remove power steering pump through bolt and remove nut and bolt from adjuster.
11. Pull pump from mounting bracket and position out of the way.
12. Disconnect lower radiator hose from water pump.
13. Position power steering pump to access mounting bracket retaining bolts and nut.

Power Steering And Air Conditioning Brackets:

14. Remove two bolts and one nut retaining mounting bracket to engine and remove bracket.
15. Remove two screws retaining air cleaner duct tube, loosen clamp at turbocharger and position duct out of the way.
16. Disconnect coolant return hose at turbocharger.

Oil Supply Line:

17. Remove bolt and brass sealing washers retaining oil supply line at engine block.
18. Raise vehicle.
19. Remove three retaining nuts and washers from exhaust pipe flange.
20. Remove two bolts retaining exhaust hanger to engine block.
21. Slide off two rubber exhaust hangers at catalyst.

Exhaust Pipe Flange:

22. Pull downward on exhaust pipe and move to left side of vehicle.
23. Disconnect oil return hose at turbocharger.
24. Disconnect coolant return hose at turbocharger.

Turbo Support Bracket:

25. Remove two retaining bolts from turbocharger support bracket.
26. Remove two bolts retaining coolant bypass tube outlet to water pump.
27. Lower vehicle.
28. Loosen retaining clamp bolt on coolant bypass tube at rear of cylinder head.
29. Remove 11 retaining nuts from exhaust manifold.

Coolant Bypass Tube:

30. Pull coolant bypass tube bracket from exhaust stud and position tube out of the way.
31. Grasp exhaust manifold, pull off studs and move assembly slightly to right side of engine compartment to clear cooling fan, and remove from vehicle.

Turbocharger Oil Passage:

32. Working on a bench, remove four nuts retaining turbocharger to exhaust manifold, separate assembly and discard gasket.

NOTE: When reinstalling turbocharger, perform the following:
^ Remove all old gaskets and sealant.
^ Use new gaskets.
^ Add 1.53 cu in (25 cc) of oil to turbo oil passage.

INSTALLATION

1. Position new gasket on exhaust manifold and install turbocharger onto studs.
2. Tighten four retaining nuts to 20 - 25 ft lb (27 - 33 Nm).

NOTE: Use only specified nuts to mount turbocharger to exhaust manifold.

3. Remove oil supply line.

Exhaust Manifold Gasket:

4. Position new exhaust gasket on cylinder head.
5. Carefully position turbocharger assembly in engine compartment and slide exhaust manifold onto studs.
6. Position heater tube bracket onto exhaust stud.

Exhaust Manifold Installation:

7. Install 11 retaining nuts onto exhaust manifold and tighten to 29 - 42 ft lb (39 - 57 Nm).
8. Tighten heater tube clamp bolt securely.
9. Raise the vehicle.
10. Position new gasket and install two retaining bolts on heater tube outlet. Tighten bolts to 14 - 19 ft lb (19 - 25 Nm).

Turbocharger Support Bracket:

11. Install two retaining bolts into turbocharger support bracket. Tighten bolts to 32 - 45 ft lb (43 - 61 Nm).
12. Connect coolant return hose.
13. Connect oil return hose and secure with clamp.
14. Position exhaust pipe onto turbocharger and start nuts and washers.
15. Install two retaining bolts on exhaust hanger at engine.
16. Slide on two rubber exhaust hangers at catalyst.

Exhaust Pipe Installation:

17. Tighten exhaust pipe retaining nuts to 18 - 24 ft lb (24 - 32 Nm).
18. Lower vehicle.

Oil Line Installation:

19. Install retaining bolt and brass washers on oil supply line and carefully position oil line into vehicle and hand-start bolt into engine block. Connect oil line to turbocharger and finger-tighten. Tighten oil line bolt to 104 - 156 in lb (12 - 18 Nm).

NOTE: Make sure that one brass washer is on each side of oil line fitting.

20. Tighten oil supply line on turbocharger to 12 - 17 ft lb (16 - 24 Nm).
21. Connect coolant supply hose.
22. Position air cleaner duct tube on turbocharger and tighten clamp,
23. Install two screws retaining air cleaner duct tube.
24. Position power steering bracket on engine and install two retaining bolts and one retaining nut and tighten to 35 - 48 ft lb (47 - 66 Nm).
25. Position power steering pump on mounting bracket and install through bolt and adjuster.
26. Connect lower radiator hose.
27. Install power steering belt.
28. Position side heat shield and install three retaining bolts finger-tight.
29. Position upper heat shield and install two retaining bolts finger-tight.

NOTE: Feed oxygen sensor wire through upper heat shield. Install wire retainer under left bolt.

30. Position lower heat shield and install three retaining bolts finger-tight.
31. Tighten all heat shield retaining bolts to 14 - 19 ft lb (19 - 25 Nm).
32. Connect EGO sensor and install connector into its retaining clip,
33. Position intercooler hose on turbocharger and secure with clamp.
34. Install throttle body air intake tube.
35. Connect negative battery cable.
36. Refill cooling system.
37. If turbocharger was replaced, perform the following before starting engine:
a. Disconnect ignition coil.
b. Crank engine for 20 seconds.
c. Connect ignition coil.
38. Start engine and run at idle for 30 - 60 seconds before driving. Check for leaks.