Turbocharger: Service and Repair

Turbocharger

REMOVAL

1. Remove the collector cover.
2. Disconnect the ground cable from battery.






3. Lift up the vehicle.
4. Drain approximately 3.0 l (3.2 US qt, 2.6 Imp qt) of coolant.
5. Lower the vehicle.
6. Remove the intercooler.
7. Lower the vehicle.
8. Lower the vehicle.
9. Separate the joint pipe from turbocharger.






10 Disconnect the engine coolant hoses from coolant filler tank.






11. Disconnect the air control hose (A), and loosen the clamp holding the intake duct to the turbocharger.






12. Remove the oil inlet pipe from the turbocharger.

CAUTION: In order to prevent damaging the oil pipe on the cylinder head side, fix the section (a) shown in the figure when loosing the oil inlet pipe flare nut, and avoid the part from rotating together while loosening the nut.









13. Disconnect the engine coolant hose from the water pipe.






14. Disconnect the oil outlet hose from the oil outlet pipe, and remove the turbocharger.






15. Remove the turbocharger stay.






INSTALLATION

1. Install the turbocharger stay.

Tightening torque:
T1: 33 N.m (3.4 kgf.m, 24.3 ft.lb)
T2: 42.5 N.m (4.3 kgf.m, 31.3 ft.lb)






2. Connect the oil outlet hose to the oil outlet pipe.






3. Connect the engine coolant hoses to the water pipe.






4. Temporarily tighten the bolts and flare nuts which secure the oil inlet pipe to the turbocharger.

NOTE: Use a new gasket.






5. Tighten the union bolts and flare nuts which secure the oil inlet pipe to the turbocharger.

CAUTION: In order to prevent damaging the oil pipe on the cylinder head side, fix the section (a) shown in the figure when tightening the oil inlet pipe flare nut, and avoid the part from rotating together while tightening the nut.






Tightening torque:
T1: 16 N.m (1.6 kgf.m, 11.8 ft.lb)
T2: 20 N.m (2.0 kgf.m, 14.8 ft.lb)






6. Tighten the bolts which hold the oil inlet pipe stay to the turbocharger.

Tightening torque: 5 N.m (0.5 kgf.m, 3.7 ft.lb)






7. Connect the air control hose (A), and install the intake duct to the turbocharger.

Tightening torque: 3 N.m (0.3 kgf.m, 2.2 ft.lb)






8. Connect the engine coolant hoses to the coolant filler tank.






9. Install the joint pipe to turbocharger.

NOTE: Replace the gasket with a new part.

Tightening torque: 42.5 N.m (4.3 kgf.m, 31.3 ft.lb)






10 Lift up the vehicle.
11. Lift up the vehicle. 11) Install the center exhaust pipe.
12. Lower the vehicle.
13. Install the intercooler.
14. Connect the battery ground terminal.






15. Fill engine coolant.
16. Install the collector cover.