Turbocharger: Service and Repair

TURBOCHARGER, REPLACE
1. Disconnect battery ground cable.
2. Drain cooling system, then mark position of hood and remove.
3. Remove four front grille attaching screws, then pull grill outward to remove.
4. Remove intercooler attaching bolts, then the intercooler.
5. Remove radiator hoses, then the radiator fan motor connector.
6. Remove front upper member, then the A/C condenser, if equipped.
7. Remove radiator attaching bolts, then the radiator.
8. Support front bumper with a suitable stand, then remove connectors, clamps and front bumper attaching bolts. Pull bumper outward, then separate bumper from damper flange.
9. Remove exhaust pipe attaching bolts, then the exhaust pipe.
10. On models with A/C, remove compressor attaching bolts, then the compressor.
11. Remove turbocharger cover, then disconnect oxygen sensor wire.
12. Remove turbocharger side cover, then lower exhaust pipe support bracket bolt.
13. Remove upper and lower exhaust pipe, then the air outlet pipe.
14. Remove air inlet hose clamp from cylinder head, then the air inlet pipe.
15. Remove oil pipe from cylinder block, then the oil drain hose.
16. Remove water pipe cylinder head clamp attaching bolt, then the water hose.
17. Remove turbocharger assembly.
18. Reverse procedure to install.

INTERCOOLER, REPLACE
1. Remove intercooler cover.
2. Remove intercooler inlet and outlet hoses.
3. Remove intercooler attaching bolts, then the intercooler.
4. Remove intercooler relief valve from intercooler.
5. Reverse procedure to install.

AIR CLEANER, REPLACE
1. Remove air flow meter bracket.
2. Remove air cleaner cap.
3. Remove air cleaner element.
4. Install new air cleaner element.
5. Install air cleaner cap, with positioning lug of air cleaner cap aligned with dent in air cleaner case.
6. Install air flow meter bracket.