Turbocharger Service

Turbocharger And Components:

REMOVAL:

1. Disconnect negative battery terminal.
2. Drain engine coolant.
3. Remove No.4 air cleaner pipe with No.1 and No.2 air cleaner hoses.

Removing Air Cleaner Pipe:

4. Disconnect the air inlet hoses and the air flow meter connector.

Disconnecting Air Hoses:

5. Loosen clamps and remove the mounting bolt along with the No.7 air cleaner hose and air flow meter/air cleaner cap assembly.
6. Disconnect the power steering idle-up air hose.

Removing Airflow Meter With Air Cleaner Hose:

7. Disconnect the oxygen sensor connector.
8. Remove the three nuts, plate washer and turbo heat insulator.

Removing Turbocharger Heat Insulator:

9. Remove the oil dipstick, bolt and dipstick guide.

Removing Dipstick Guide:

10. Remove the No.1 air cleaner pipe from the turbocharger by removing the clamps for No.5 and No.6 air cleaner hoses.

Removing No.1 Air Cleaner Pipe:

11. Remove three nuts and the front exhaust pipe.

Disconnecting Front Exhaust Pipe:

12. Remove the front exhaust pipe clamp.

Removing Exhaust Pipe Clamp:

13. Disconnect the exhaust pipe from the exhaust manifold and remove the gasket.
14. Remove turbo oil pipe mounting nuts and mounting union.
15. Remove turbocharger stay.

Removing Turbocharger Stay:

16. Remove No.2 turbocharger stay.

Removing No.2 Turbocharger Stay:

17. Remove No.1 turbocharger water hose from water outlet housing.

Disconnecting No.1 Water Hose From Water Outlet Housing:

18. Disconnect union bolt and gaskets.

Disconnect Water Union Pipe:

19. Remove four nuts, turbocharger and gasket.

Removing Turbocharger Mounting Nuts:

20. Remove No.1 turbo water pipe.

Remove No.1 Turbo Water Pipe:

21. Remove two nuts, turbo oil pipe and gasket.

Removing Turbo Oil Pipes:

22. Remove four nuts, turbine outlet elbow and gasket.

Removing Turbocharger 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 Turbocharger Shaft Bearings:

2. Install a new gasket and the turbine outlet elbow to the turbocharger. Torque the four mounting nuts to 32 ft.lbs. (43 N-m).
3. Install turbo oil pipe with new gasket on the turbocharger. Torque the two mounting nuts and bolt to 9 ft.lbs. (13 N-m).
4. Install No.1 turbo water pipe with a new gasket to the turbocharger. Torque the two mounting nuts and bolt to 5.4 ft.lbs. (7.4 N-m).

Installing No.2 Turbo Oil Pipe:

5. Face a new gasket on the exhaust manifold so the protrusion is facing the rear. Place a new gasket on the oil return hole of the cylinder block.

Proper Installation Of Turbocharger Mounting Gasket:

6. Install the turbocharger on the exhaust manifold and oil pipe stud bolts. Do not tighten the four mounting nuts.

Installing Turbocharger Oil Pipe:

7. Attach oil pipe flange nuts and union bolt to the engine. Torque turbo mounting nuts to 33 ft.lbs. (44 N-m).
8. Tighten oil pipe nuts and union bolt.

TIGHTENING TORQUE:

Oil Pipe To Turbo: 9 ft.lbs. (13 N-m)
Oil Pipe Union Bolt: 25 ft.lbs. (34 N-m)

9. Connect the water union pipe with the union bolt and two new gaskets.
10. Install No.1 turbo water hose to water outlet housing.
11. Install No.2 turbocharger stay
12. Install turbocharger stay. Torque the bolt to the turbo to 59 ft.lbs. (79 N-m) and the bolt to the engine bracket to 43 ft.lbs. (58 N-m).
13. Install a new gasket on the front exhaust pipe and install the front exhaust pipe to the exhaust manifold with three nuts. Torque the nuts to 46 ft.lbs. (62 N-m) evenly.
14. Install the front exhaust pipe clamp.
15. Install the No.1 air cleaner pipe with No.6 air cleaner hose to the No.5 air cleaner hose and turbocharger.
16. Connect the No.1 air cleaner pipe to bracket with the bolt. Torque the bolt to 9 ft.lbs. (13 N-m).
17. Tighten the No.5 and No.6 air hose clamps.
18. Install a new O-ring on the dipstick guide and install the dipstick guide. Install the oil dipstick.
19. Install the turbo heat insulator with the three plate washers and nuts.
20. Connect oxygen sensor connector.
21. Install the No.7 air cleaner hose with the air flow meter/air cleaner cap assembly.
22. Install mounting bolt and tighten clamps.
23. Connect the PS idle-up hose.
24. Connect the air flow meter connector, PCV hose and three air hoses.
25. Install No.4 air cleaner pipe with No.1 and No.2 air cleaner hoses.
26. Fill engine with coolant.
27. Reconnect negative battery terminal.
28. Start engine and check for exhaust and coolant leaks.