Turbocharger: Service and Repair

1. Remove hoses, ducts and heat shields that will interfere with turbocharger removal.
2. Remove oxygen sensor, then disconnect turbocharger from catalytic converter.
3. Disconnect oil inlet and outlet pipes from turbocharger unit.
4. Disconnect EGR vacuum hose, then loosen retainers at front of engine.
5. Disconnect turbocharger at support bracket lower clamp.
6. Remove exhaust manifold and turbocharger as an assembly.
7. Separate turbocharger from exhaust manifold.
8. Reverse procedure to install, noting the following:
a. When assembling turbocharger to exhaust manifold, ensure that all mating surfaces are cleaned and properly aligned, then torque attaching bolts to 33 ft. lbs.
b. Install new gasket between turbocharger and catalytic converter.
c. Torque turbocharger to catalytic converter attaching bolts to 22 ft. lbs.
d. Install new inlet and outlet gaskets, then squirt oil into inlet opening.
e. Before attaching oil line to turbocharger, purge air from oil line by rotating engine with ignition system disconnected.
f. Lubricate EGR to exhaust manifold coupling nut with lubricant MIL-A-907B or equivalent.