Turbocharger: Service and Repair

REMOVAL

Turbocharging System:

Exhaust Manifold/Turbocharger Assembly:

1. Be sure engine and exhaust system are cool enough to touch. Drain engine coolant.
2. Remove heat shielding from exhaust manifold and turbocharger.
3. Disconnect air hoses, coolant hoses, and oil lines from turbocharger.
4. Disconnect EGR pipe and remove oxygen sensor from exhaust manifold.
5. Disconnect front exhaust pipe from turbocharger exhaust outlet and pull it away. It may also be necessary to disconnect front pipe from catalytic converter and remove it completely.
6. Remove lower bracket from turbocharger.
7. Remove turbocharger and exhaust manifold from engine as an assembly, then separate turbo from exhaust manifold.

CAUTION: Observe the following precautions when servicing the turbocharger.
^ Do not drop turbocharger.
^ Don't use wastegate actuator rod to carry the unit.
^ Cover inlets and outlets to prevent dirt or other contaminants from getting into turbo housing or bearing assembly.
^ Do not bend wastegate actuator rod or actuator bracket.
^ Store turbocharger with impeller/compressor shaft in horizontal position.

DISASSEMBLY

Turbocharger Assembly - Serviceable Parts:

1. Remove exhaust joint pipe from turbocharger.

Aligning Turbine Housing And Compressor Housing W/Bearing Assembly:

2. Set turbocharger assembly on a flat surface and mark relative positions of turbine housing and bearing hub oil outlet pipe for reference during re-assembly (mark "A", see illustration).
3. Note and mark position of compressor housing relative to bearing hub assembly, for reference during re-assembly (mark "B", see illustration).
4. Remove wastegate actuator and compressor housing retainer plates, and separate compressor housing from bearing hub assembly.
5. Remove turbine housing retainer plates and separate turbine housing from bearing hub assembly.


ASSEMBLY NOTES

Correct Sealant Application:

1. Clean sealer from compressor and turbine housings and apply a fresh, thin bead of appropriate sealer.
2. Carefully align bearing housing with turbine and compressor housings according to marks previously made.

Correct Positioning Of Turbine Retainer Plates:

3. Install turbine housing retainer plates as shown in illustration, to prevent heat distortion. Torque bolts to specification.

20 - 21 ftlbs (27 - 29 Nm)

Installing Compressor Retainer Plates:

4. Install compressor housing retainer plates with rounded edges facing compressor housing. Torque bolts to specification.

37 - 46 inlbs (4.2 - 5.2 Nm)

INSTALLATION NOTES
1. Install in reverse order of removal.
2. Prior to installation, add approx. 1 oz. (25 - 30cc) of clean engine oil to bearing hub assembly oil inlet.
3. Replace manifold to cylinder head nuts and turbo to manifold nuts. Tighten fasteners to the following torque specifications.

MANIFOLD TO CYL. HEAD [1] 25 - 34 ftlb (34 - 46 Nm)
TURBOCHARGER TO MANIFOLD 23 - 30 ftlb (31 - 41 Nm)
TURBOCHARGER TO JOINT PIPE 27 - 46 ftlb (37 - 63 Nm)
WATER PIPE TO TURBOCHARGER 25 - 28 ftlb (34 - 38 Nm)
OIL INLET PIPE TO ENGINE BLOCK 23 - 34 ftlb (31 - 46 Nm)

[1] Tighten in three steps.