Exhaust Manifold: Service and Repair
Turbocharger and Exhaust Manifold Removal and InstallationTurbocharger And Exhaust Manifold (Part 1):
Turbocharger And Exhaust Manifold (Part 2):
Removal
1. Drain the engine coolant.
2. Remove the cowl cover and under-cowl panel.
3. Remove the air cleaner housing assembly.
4. Remove the charge air cooler.
5. Remove the warm up catalytic converter.
6. Remove the under-hood fuse/relay box from the bracket.
7. Remove the master cylinder reservoir (A) from the bracket, then remove the bracket (B).
8. Remove the heater hoses (A), then open the cable clamp, and remove the heater valve cable (B).
9. Remove the heater valve mounting bolt (C).
10. Remove the air bypass outlet pipe (A).
11. Remove the evaporative emission (EVAP) canister hose (A), then remove the intake air duct (turbocharger inlet pipe) (B).
12. Remove the intake air ducts (charge air cooler inlet hose/turbocharger outlet pipe assembly).
13. Remove the breather hose (A) and water bypass hose (B), then remove the water bypass line mounting bolt (C).
14. Disconnect the turbocharger waste gate control solenoid valve connector and turbocharger boost control solenoid valve connector.
15. Remove the vacuum hose (A), vacuum line mounting bolt (B), and solenoid valve bracket mounting bolt (C), then loosen the solenoid valve bracket mounting bolt (D), and remove the solenoid valve bracket (E).
16. Remove the charge air cooler bracket.
17. Remove the water bypass hose (A) and vacuum hoses (B).
18. Remove the water bypass pipe from the turbocharger.
19. Remove the intake air duct (turbocharger inlet connecting tube).
20. Raise the vehicle on the lift to full height.
21. Remove the oil return pipe (A), then remove 16 x 1.5 mm bolt (B) at the oil feed pipe.
22. Remove the turbocharger bracket.
23. Lower the vehicle on the lift.
24. Remove the oil feed pipe.
25. Remove the turbocharger assembly, then seal the air inlet, air outlet, oil line hole, and water line hole with tape.
NOTE: Use care when handling the turbocharger assembly. Do not turn the actuator rod adjusting nut, or touch the impeller.
26. Remove the water bypass hoses (A), then remove the exhaust manifold (B).
27. Remove the water bypass pipe (C) and water bypass hose (D) from the exhaust manifold.
Installation
1. Install the water bypass pipe (A) with a new O-ring (B), then install the water bypass hose (C).
2. Install the exhaust manifold (D) with a new gasket (E) and new self-locking nuts (F) and bolts (G), and tighten the bolts and nuts in a crisscross pattern in two or three steps, beginning with the inner bolt.
3. Install the water bypass hoses (H).
4. Pour new engine oil into turbocharger oil line.
5. Install the turbocharger assembly (A) with a new gasket (B).
NOTE: Use care when installing the turbocharger assembly. Do not turn the actuator rod adjusting nut, or touch the impeller.
6. Check the oil feed pipe (A) for clogs. If it is clogged, clean or replace the pipe. Install the oil feed pipe with new washers (B), and loosely tighten the 10 x 1.25 mm nut (C).
7. Raise the vehicle on the lift to full height.
8. Install the turbocharger bracket.
9. Check the bolt (A) and oil return pipe (B) for clogs. If they are clogged, clean or replace the bolt and/or pipe.
10. Loosely tighten the 16 x 1.5 mm bolt with new washers (C), then install the oil return pipe with new gaskets (D).
11. Lower the vehicle on the lift.
12. Tighten the 10 x 1.25 mm nut.
13. Raise the vehicle on the lift to full height.
14. Tighten the 16 x 1.5 mm bolt.
15. Lower the vehicle on the lift.
16. Install the intake air duct (turbocharger inlet connecting tube).
17. Install the water bypass pipe (A) with new gasket (B).
18. Install the water bypass hose (A) and vacuum hoses (B).
19. Install the charge air cooler bracket.
20. Install the solenoid valve bracket (A) and vacuum hose (B), then install the vacuum line mounting bolt (C).
21. Connect the turbocharger waste gate control solenoid valve connector and turbocharger boost control solenoid valve connector.
22. Install the breather hose (A) and water bypass hose (B), then install the water bypass line mounting bolt (C).
23. Install the intake air ducts (charge air cooler inlet hose/turbocharger outlet pipe assembly) (A) with new gasket (B).
24. Install the intake air duct (turbocharger inlet pipe) (A), then install the evaporative emission (EVAP) canister hose (B).
25. Install the air bypass outlet pipe (A).
26. Install the heater valve mounting bolt (A).
27. Install the heater cable (B), and lock the clamp, then install the heater hoses (C).
28. Install the bracket (A), then install the master cylinder reservoir (B).
29. Install the under-hood fuse/relay box to the bracket.
30. Install the warm up catalytic converter.
31. Install the charge air cooler.
32. Install the air cleaner housing assembly.
33. Install the cowl cover and under-cowl panel.
34. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.