Turbocharger Service

REMOVAL:

1. Disconnect negative battery terminal.
2. Remove lower engine covers.
3. Drain engine coolant from radiator.
4. Remove lower suspension crossmember.
5. Remove front exhaust pipe.
6. Remove center engine mounting member.
7. Remove front engine mount insulator and bracket.
8. Remove clutch slave cylinder. Do not disconnect fluid line.
9. Remove alternator.
10. Remove A/C compressor and lay to the side of the engine compartment. Do not disconnect refrigerant hoses.
11. Remove catalytic converter from engine.
12. Remove the seven clips and cool air inlet from the Intercooler protector.

Removing Cool Air Inlet:

13. Remove the three bolts and Intercooler protector.

Removing Protector From Intercooler:

14. Remove the two Intercooler mounting bolts and disconnect the air inlet hoses.

Removing Intercooler From Engine:

15. Lift the Intercooler from the engine.
16. Remove the three bolts and the turbo heat insulator.

Removing Turbo Heat Insulator:

17. Remove the Oxygen Sensor and gasket from the turbine elbow.

Removing Oxygen Sensor:

18. Remove the dipstick.
19. Remove LH and RH heat insulators from the turbine elbow.

Removing Heat Insulators From Turbine Outlet Elbow:

20. Disconnect hoses from Turbocharger:

Disconnecting Water Hoses:

a. Water hose from radiator
b. Water hose from water inlet
c. Water bypass hose from turbo water pipe
d. Vacuum hose from Wastegate Actuator
21. Disconnect oil return hose (e), from turbo oil pipe.

Oil Return Hose:

22. Remove three bolts and the turbocharger mounting stay.

Removing Turbocharger Stay:

23. Remove the union bolt and gaskets for No.1 turbo oil pipe.

Removing No.1 Turbo Oil Pipe:

24. Remove the four mounting nuts and the Turbocharger from the exhaust manifold. Remove old gasket and discard.

Removing Turbocharger From Exhaust Manifold:

25. Remove oil pipe and gasket from turbo.

Removing Oil Pipe From Turbo:

26. Remove two nuts, two bolts, water pipe and gasket from turbo.

Removing Water Pipe From Turbo:

27. Remove the side bearing plate and gasket.

Removing Side Bearing Housing Plate:

28. Remove the six nuts and outlet elbow with gasket from the turbo.

Removing Turbine Outlet Elbow:

INSTALLATION:

1. Put 20cc (1.2 cu.in.) of engine oil into the turbocharger oil inlet and turn the impeller wheel by hand to spread the oil to the shaft bearings.

Lubricating Turbo Shaft Bearings:

2. Install turbine outlet elbow with a new gasket. Torque the six nuts to 47 ft.lbs. (64 N-m).
3. Install a new gasket and the side bearing housing plate. Torque the two nuts to 9 ft.lbs. (11 N-m).
4. Install the turbo water pipe with a new gasket. Torque the two nuts and two bolts to 9 ft.lbs. (11 N-m).
5. Align the holes of the new oil pipe gasket, install the oil pipe and start the mounting nuts. DO NOT tighten the nuts yet.

Installing Turbo Oil Pipe Gasket:

6. Install a new mounting gasket and install the turbocharger with the four nuts. DO NOT tighten the nuts yet.

Installing Turbocharger On Exhaust Manifold:

7. Install the oil pipe with the union bolt and new gaskets. DO NOT tighten the bolt yet.

Installing Oil Pipe Union Bolt:

8. Torque the four turbocharger mounting nuts to 47 ft.lbs. (64 N-m).
9. Torque the two nuts holding the oil pipe to the turbocharger to 13 ft.lbs. (17 N-m).

Tightening Oil Pipe To The Turbocharger:

10. Torque the oil pipe union bolt to 38 ft.lbs. (51 N-m).
11. Torque the oil pipe mounting bolt to 32 ft.lbs. (43 N-m).
12. Install the turbocharger stay with the three mounting bolts. Torque the turbo bolt to 51 ft.lbs. (69 N-m) and the cylinder block bolts to 43 ft.lbs. (59 N-m).
13. Connect hoses:
a. Water hose from radiator
b. Water hose from water inlet
c. Water bypass hose from turbo water pipe
d. Vacuum hose from Wastegate Actuator
e. Turbo oil return pipe hose
14. Install LH and RH side turbine elbow heat insulators.
15. Install dipstick.
16. Install Oxygen Sensor with new gasket. Torque the sensor nuts to 33 ft.lbs. (44 N-m). Reconnect sensor wire.
17. Install turbo heat insulator.
18. Install Intercooler on engine and connect air inlet hoses. Tighten clamps.
19. Install the Intercooler protector.
20. Install the cool air inlet with the seven clips.
21. Install the catalytic converter.
22. Install A/C compressor and idler pulley. Adjust drivebelt tension.
23. Install the alternator. Adjust drivebelt tension.
24. Install the clutch slave cylinder.
25. Install the front engine mounting bracket and insulator.
26. Install the center engine mounting member.
27. Install the front exhaust pipe.
28. Install the lower suspension crossmember.
29. Install the air cleaner cap.
30. Refill the engine with coolant.
31. Reconnect negative battery cable.
32. Install the lower engine covers.
33. Check engine oil level.
34. Start the engine and check for vacuum or coolant leaks.