Turbocharger: Service and Repair

1. Disconnect battery ground cable. If vehicle is equipped with an automatic transmission, the starter may be removed to facilitate the removal of the turbocharger.
2. Remove lower engine and transmission cover plate, if equipped. Loosen the inner clamps of the stabilizer bar and move stabilizer downward.
3. Disconnect oil return line from turbocharger.
4. Loosen engine carrier center bolt, then disconnect heat shield and oil return line from turbocharger.
5. Remove air hoses between turbocharger and intake manifold and between turbocharger and air cleaner.
6. Disconnect oil supply line and exhaust pipe from turbocharger.

Fig. 32 Turbocharger replacement:

7. Remove turbocharger-to-exhaust manifold attaching bolts and the turbocharger, Fig. 32.
8. Reverse procedure to install, noting the following:
a. Apply suitable grease to turbocharger-to-exhaust manifold attaching bolts.
b. Tighten bolts hand tight in sequence shown in Fig. 32, then torque bolts in sequence to the following specifications. Torque turbocharger-to-manifold bolts to 30 ft. lbs. (40 Nm), oil return line attaching bolts to 18 ft. lbs. (25 Nm).
c. Prior to connecting oil supply line, fill turbocharger connection branch with engine oil.
d. Thoroughly clean the mating surfaces of the turbocharger and the exhaust manifold. Check these surfaces carefully for damage, as no gasket is used and damage may cause leakage.
e. Following completion of installation, run engine at idle speed for one minute to properly distribute oil supply.