Turbocharger: Service and Repair

REMOVAL
Before servicing the turbocharger, ensure turbocharger exhaust pipes have cooled.
1. Disconnect battery ground cable.
2. Remove turbocharger heat protector.
3. Remove oxygen sensor from catalytic converter.
4. Disconnect catalytic converter from turbocharger assembly.
5. Disconnect oil hose from oil return line and timing chain case.
6. Remove oil line and oil filter bracket from turbocharger assembly.
7. Remove air intake pipe attaching bolt.
8. Remove turbocharger assembly attaching nuts, then the turbocharger from exhaust manifold.

INSPECTION
Turbocharger
1. Check turbocharger case for cracks or damage. Replace turbocharger assembly, if necessary.
2. Check turbine and compressor wheels for wear and/or damage.
3. Ensure turbine and compressor wheels rotate smoothly.
Wastegate Actuator
1. Using a suitable hand held pressure pump, apply pressure to the wastegate actuator through the nipple.
2. Ensure actuator operates smoothly without binding.

Fig. 1 Turbocharger assembly.:

Fig. 2 Turbocharger assembly.:

INSTALLATION
Reverse removal procedure for turbocharger installation, noting the following:
1. Torque all turbocharger parts to specifications shown in Figs. 1 and 2.
2. Before oil line flare nut is installed, pour clean engine oil into the turbocharger.
3. Ensure oil and air hoses are correctly installed and securely clamped.
4. Do not reuse heat-damaged, corroded or deformed exhaust manifold or turbocharger gaskets.