Turbocharger: Service and Repair

TURBOCHARGER

REMOVAL
1. Disconnect the battery negative cables.
2. Raise vehicle on hoist.





3. Disconnect the exhaust pipe from the turbocharger elbow.
4. Remove the bolts from the turbocharger oil drain tube.
5. Disconnect wastegate command valve connector.
6. Remove two lower turbocharger mounting nuts.
7. Lower vehicle.
8. Disconnect the turbocharger air inlet hose.
9. Disconnect the turbocharger oil supply line from the turbocharger.
10. Disconnect the charge air cooler inlet pipe from the turbocharger compressor outlet.





11. Remove two upper turbocharger mounting nuts.
12. Remove the turbocharger and gasket from the exhaust manifold.
13. If the turbocharger is not to be installed immediately, cover the opening to prevent material from entering into the manifold.
14. If replacing the turbocharger, transfer the turbocharger oil supply fitting to the new assembly. Tighten fitting to 36 Nm (27 ft. lbs.).
15. Clean and inspect the sealing surface.

CAUTION: The Wastegate Command Valve, and Command Valve O-ring are the only serviceable components on the turbocharger. The turbocharger itself is serviced as a component. Do not attempt to repair the turbocharger as turbocharger and/or engine damage can result.

TURBOCHARGER OIL DRAIN TUBE
1. Disconnect negative battery cables.
2. Raise vehicle on hoist.





3. Remove two turbocharger oil tube mounting bolts.
4. Pulling upward, remove the turbocharger drain tube from the engine block.

CLEANING

WARNING: To prevent damage or personal injury, do not use a combustible cleaner to clean the turbo charger.

Clean the turbocharger, turbocharger oil drain tube flange, and exhaust manifold mounting surfaces with a suitable scraper.

INSPECTION
Visually inspect the turbocharger and exhaust manifold gasket surfaces. Replace stripped or eroded mounting studs.





1. Visually inspect the turbocharger for cracks. The following cracks are NOT acceptable:
- Cracks in the turbine and compressor housing that go completely through.
- Cracks in the mounting flange that are longer than 15 mm (0.6 inch).
- Cracks in the mounting flange that intersect bolt through-holes.
- Two (2) Cracks in the mounting flange that are closer than 6.4 mm (0.25 inch) together.

2. Visually inspect the impeller and compressor wheel fins for nicks, cracks, or chips. Note: Some impellers may have a factory placed paint mark which, after normal operation, appears to be a crack. Remove this mark with a suitable solvent to verify that it is not a crack.
3. Visually inspect the turbocharger compressor housing for an impeller rubbing condition. Replace the turbocharger if the condition exists.





4. Measure the turbocharger axial end play:
a. Install a dial indicator as shown in. Zero the indicator at one end of travel.
b. Move the impeller shaft fore and aft and record the measurement. Allowable end play is 0.026 mm (0.0001 inch) MINIMUM and 0.127 mm (0.005 inch) MAXIMUM. If the recorded measurement falls outside these parameters, replace the turbocharger assembly.





5. Measure the turbocharger bearing radial clearance:
a. Insert a narrow blade or wire style feeler gauge between the compressor wheel and the housing.
b. Gently push the compressor wheel toward the housing and record the clearance.
c. With the feeler gauge in the same location, gently push the compressor wheel away from the housing and again record the clearance.
d. Subtract the smaller clearance from the larger clearance. This is the radial bearing clearance.
e. Allowable radial bearing clearance is 0.33 mm (0.013 inch) MINIMUM and 0.50 mm (0.020 inch) MAXIMUM. If the recorded measurement falls outside these specifications, replace the turbocharger assembly.

INSTALLATION





1. Using a new gasket, install the turbocharger. Tighten the turbocharger mounting nuts to 43 Nm (32 ft. lbs.) torque.
2. Raise vehicle on hoist.
3. Using a new gasket, install the oil drain tube to the turbocharger. Tighten the drain tube bolts to 24 Nm (18 ft. lbs.) torque.





4. Connect the exhaust pipe to the turbocharger and tighten the bolts to 11.3 Nm (100 inch lbs.) torque.
5. Connect wastegate command valve connector.
6. Lower the vehicle.
7. Pre-lube the turbocharger. Pour 50 to 60 cc (2 to 3 ounces) clean engine oil in the oil supply line fitting. Carefully rotate the turbocharger impeller by hand to distribute the oil thoroughly.
8. Install and tighten the oil supply line to 24 Nm (18 ft. lbs.) torque.
9. Position the charge air cooler inlet pipe to the turbocharger. With the clamp in position, tighten the clamp nut to 11 Nm (95 inch lbs.) torque.
10. Position the air inlet hose to the turbocharger. Tighten the clamp to 4 Nm (35 inch lbs.) torque.
11. Connect the battery negative cables.
12. Start the engine to check for leaks.

TURBOCHARGER OIL DRAIN TUBE
1. Raise vehicle on hoist.





2. Install new turbocharger oil drain tube O-rings. Lubricate O-rings with engine oil.
3. Install turbocharger oil drain tube into engine block.
4. Using a new gasket, install two oil drain tube mounting bolts. Tighten to 24 Nm (18 ft. lbs.).
5. Lower vehicle.
6. Connect negative battery cable.