Turbocharger: Service and Repair

WARNING: The turbocharger operates at high speed. keep fingers and other objects away from openings to avoid injury.

Before starting any turbocharger unit service/removal procedure, clean the area around the turbocharger assembly with a non-caustic solution. Cover the openings at the turbocharger assembly connections to prevent entry of foreign material while the turbocharger is off the engine. Interruption or contamination of the oil supply to the bearings in the center housing which support the rotating assembly can result in major turbocharger damage.

When removing the turbocharger assembly, take special care not to bend, nick, or in any way damage the compressor wheel blades. Damage may result in rotating assembly imbalance and failure of the bearings and oil seal. Any time a basic engine bearing (main bearing, connecting rod bearing, camshaft bearing) has been damaged in a turbocharged engine, the oil and oil filter should be changed as a part of the service procedure. In addition, the turbocharger should be flushed with clean engine oil to reduce the possibility of contamination. Any time a turbocharger assembly has been removed, gently spin the turbine wheel before reassembly to ensure that rotating assembly does not bind.

REMOVAL:

1. Disconnect the negative battery cable.
2. Drain the coolant from the radiator.

Compressor Housing Air Outlet Hose:

3. Remove the air hose from the compressor housing (outlet) of the turbocharger.

Compressor Housing Air Inlet Hose:

4. Remove the air hose from the air inlet side of the turbocharger assembly.

Turbocharger Heat Shield:

5. Remove the heat shields from the exhaust manifold and turbocharger assembly.

EGO Sensor Electrical Connector:

NOTE: It may be necessary to disconnect the EGO sensor electrical connector and move the wiring assembly away from the heat shield assembly.

Oil Feed Line:

6. Move the oil feed line from the turbocharger assembly.

Oil Return Line:

7. Remove the oil return line from the turbocharger assembly.

Coolant Inlet Hose:

8. Remove the coolant inlet hose from the turbocharger assembly.

Coolant Outlet Hose:

9. Remove the coolant outlet hose from the turbocharger assembly.

EGR Tube:

10. Remove the EGR tube from the exhaust manifold.

Turbo Boost Control Solenoid Valve:

11. Disconnect the [1][2]turbo boost control solenoid valve electrical connector.

Turbo Boost Control Solenoid Valve Air Hose:

12. Remove the air tube from the [1][2]turbo boost control solenoid valve at the turbocharger outlet air hose.

Turbocharger Assembly Retaining Bracket:

13. Remove the mounting bolt from the retaining bracket under the turbocharger assembly.
14. Discharge the air conditioning system.
15. Remove the refrigerant line from the head of the compressor.
16. Remove the exhaust gas oxygen sensor.
17. Remove the converter inlet pipe from the turbocharger joint pipe.

Turbocharger Assembly And Exhaust Manifold:

18. Remove the exhaust manifold and the turbocharger as an assembly.

Turbocharger Assembly:

19. Remove the exhaust manifold, the turbocharger to converter inlet pipe joint pipe and heat shield assembly from the turbocharger.

INSTALLATION:

1. Install the joint pipe and heat shield assembly onto the turbocharger and torque the mounting nuts to 37-63 Nm (27-46 lb-ft).
2. Install the exhaust manifold onto the turbocharger and torque the mounting nuts to 27-39 Nm (20-29 lb-ft).
CAUTION: Replace the exhaust manifold-to turbocharger gasket and/or joint pipe gasket if bent or cracked and only use specified nuts to mount the exhaust manifold and joint pipe to the turbocharger.
3. Install the exhaust manifold and turbocharger as an assembly into the vehicle.
4. Install the converter inlet pipe onto the joint pipe.
5. Install the mounting bolt to the retaining bracket under the turbocharger assembly.
6. Install the oil return line and coolant outlet hose to the turbocharger assembly.
7. Install the air tube to the turbocharger outlet air hose.
8. Reconnect the [1][2]turbo boost control solenoid valve electrical connector.
9. Install the exhaust gas oxygen sensor into the vehicle.
NOTE: To facilitate the remaining installation procedure, leave the wiring assembly out of the way of the heat shield assembly (step five of this removal procedure).
10. Install the EGR tube onto the exhaust manifold.
11. Install the coolant inlet hose onto the turbocharger assembly.

Oil Inlet Fitting:

12. Install the oil feed line onto the turbocharger assembly.
NOTE: When reinstalling the turbocharger, add 25 ml (.85 fl oz) of engine oil in the oil passage of the turbocharger before the oil feed line is installed.
13. Install the heat shields onto the exhaust manifold and turbocharger assembly.
14. Install the air hose onto the air inlet (compressor housing) of the turbocharger.
15. Install the air hose onto the air outlet side (compressor housing) of the turbocharger.
16. Reconnect the EGO sensor electrical connector and install the wiring assembly.
17. Install the refrigerant lines onto the head of the compressor.
18. Recharge the refrigerant system.
19. Fill the radiator with appropriate engine coolant.
20. Install the negative battery cable.
21. After replacing the turbocharger, perform the following:
a. Disconnect the electrical connector from the ignition coil.
b. Crank the engine for approximately 20 seconds.
c. Reconnect the electrical connector to the ignition coil.