Turbocharger: Service and Repair

Removing Air Pipes:

REMOVAL

1. Disconnect battery ground.
2. Remove air cleaner upper cover and filter.
3. Loosen clamps and remove both air pipes.
4. Disconnect fuel supply and return lines.
5. Disconnect vacuum line from fuel pressure regulator.

Disconnecting Cruise Control:

6. Disconnect cable from cruise control motor.
7. Remove spark plug cable from plug ends.
8. Unscrew distributor cap.

Removing Fuel Rail:

9. Remove fuel rail attaching screws from valve cover.
10. Lift off fuel rail with injectors, injector wiring and ignition spark plug cables. Set aside.
11. Disconnect throttle cable from throttle body.
12. Remove all vacuum lines from intake manifold.

Intake Manifold Removal:

13. Remove intake manifold and throttle body.
14. From under vehicle, remove splashguard and drain cooling system.
15. Remove alternator ventilation hose.
16. Remove coolant pump and bracket from body.

Turbocharger Flange:

17. Remove exhaust flange retaining bolts from turbocharger.
18. Remove exhaust flange from turbine housing.

Removing Turbocharger:

19. Disconnect coolant and oil lines from turbocharger.
20. Remove air intake cowl from compressor end of turbocharger and intercooler air pipe.
21. Remove motor mount shield.

Removing Turbocharger:

22. Remove turbocharger support bracket under engine.
23. Remove from vehicle.


INSTALLATION

Reverse procedure to install with the following additions.

1. Use all new seals.
2. Make sure all seals are installed correctly.
3. Check locknuts for looseness and replace if necessary.
4. All bolts in securing exhaust flanges on turbo should be coated with a high temperature anti-seize compound (i.e. Optimoly HT).