Turbocharger: Service and Repair

TURBOCHARGER

REMOVAL - TURBOCHARGER

CAUTION: IF TURBOCHARGER IS REPLACED DUE TO A BEARING FAILURE, REPLACEMENT OF THE OIL PRESSURE FEED LINE IS REQUIRED. OIL RETURN TUBE SHOULD BE CLEANED ALSO.

NOTE: The turbocharger and exhaust manifold are serviced as an assembly. Do Not attempt to remove the turbocharger from the exhaust manifold. Exhaust leaks will result. It is recommended that the turbocharger elbow be replaced along with the turbocharger/exhaust manifold assembly.

1. Disconnect negative battery cable.
2. Drain cooling system.
3. Remove air cleaner housing and lid.





4. Disconnect clean air hose from turbocharger (Fig. 5).
5. Disconnect throttle and speed control cables at throttle body.
6. Disconnect electrical connectors from the following components:
^ Inlet Air Temperature (IAT) Sensor
^ MAP Sensor
^ IAC Motor
^ Throttle Position Sensor
^ Ignition Coil Capacitor
^ Upstream Oxygen Sensor





7. Disconnect air inlet hose at throttle body (Fig. 6).
8. Disconnect vacuum hoses at throttle body and upper intake manifold.





9. Remove upper intake manifold support bracket (Fig. 7).
10. Remove upper intake manifold.

CAUTION: Cover lower intake manifold opening with suitable cover to prevent any foreign objects from entering.





11. Remove turbocharger upper heat shield (Fig. 11).





12. Disconnect oil supply line at turbocharger (Fig. 8).
13. Remove coolant return line (Fig. 8).
14. Disconnect vacuum hoses from turbocharger.
15. Raise vehicle on hoist.
16. Disconnect muffler ground strap. Remove muffler.
17. Disconnect downstream oxygen sensor.





18. Remove fasteners securing catalytic converter to exhaust manifold (Fig. 9).
19. Remove catalytic converter and intermediate pipe as an assembly.





20. Remove turbocharger to charge air cooler hose assembly (Fig. 10).
21. Remove turbocharger elbow support bracket (Fig. 11).
22. Remove turbocharger support bracket (Fig. 11).
23. Remove oil return tube (Fig. 8).
24. Remove turbocharger coolant supply line (Fig. 8).
25. Remove turbocharger lower heat shield (Fig. 8).
26. Remove turbocharger elbow (Fig. 11).
27. Remove lower exhaust manifold fasteners that are accessible while vehicle is on hoist.
28. Lower vehicle.
29. Remove upper exhaust manifold fasteners.
30. Remove turbocharger exhaust manifold assembly from above/between the engine and cowl panel.
31. Remove and discard exhaust manifold gasket.

INSPECTION - TYPICAL TURBOCHARGER
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.





3. Visually inspect the turbocharger compressor housing for an impeller rubbing condition (Fig. 12). Replace the turbocharger if the condition exists.
4. Measure the turbocharger axial end play:
a) Install a dial indicator. Zero the indicator at one end of travel.
a) Move the impeller shaft fore and aft and record the measurement. Allowable end play is 0.038 mm (0.0015 inch) MIN. and 0.089 mm (0.0035 inch) MAX. If the recorded measurement falls out side 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.
a) 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 0.326 mm (0.0128 inch) MIN. and 0.496 mm (0.0195 inch) MAX. If the recorded measurement falls outside these specifications, replace the turbocharger assembly.

INSTALLATION - TURBOCHARGER

CAUTION: IF TURBOCHARGER IS REPLACED DUE TO A BEARING FAILURE, REPLACEMENT OF THE OIL PRESSURE SUPPLY LINE IS REQUIRED. OIL RETURN TUBE SHOULD ALSO BE CLEANED.

NOTE: The turbocharger and exhaust manifold are serviced as an assembly. Do Not attempt to remove the turbocharger from the exhaust manifold. Exhaust leaks will result. It is recommended that the turbocharger elbow be replaced along with the turbocharger exhaust manifold assembly.

1. Clean gasket sealing surfaces. Replace exhaust manifold gasket. DO NOT APPLY SEALER TO GASKET.

NOTE: Stainless steel layer of exhaust manifold gasket goes against cylinder head, graphite layer of gasket goes against manifold surface.

2. Turbocharger exhaust manifold assembly is installed from between the engine and brake master cylinder (Fig. 9).





3. Position turbocharger/Exhaust manifold assembly in place. Gradually tighten fasteners, starting at center and progressing outward in both directions to 28 Nm (250 inch lbs.) (Fig. 13). Raise and lower vehicle for fastener access as necessary. Repeat tightening procedure until all fasteners are at specified torque.
4. Install generator heat shield.





5. Install coolant return line. Install NEW washers (Fig. 14). Torque banjo fitting bolt to 37 Nm (27 ft. lbs.) (Fig. 8).
6. Install turbocharger coolant supply line. Install NEW washers (Fig. 14). Torque banjo fitting bolt to 37 Nm (27 ft. lbs.). Torque flared fitting to 31 Nm (23 ft. lbs.) (Fig. 8).
7. Install turbocharger elbow. Torque fasteners to 28 Nm (250 inch lbs.) (Fig. 11).
8. Loosely install turbocharger upper heat shield and fasteners (Fig. 11).
9. Install turbocharger support bracket. Torque M8 fasteners to 28 Nm (250 inch lbs.) and M10 fasteners to 54 Nm (40 ft. lbs.) (Fig. 11).
10. Replace oil return tube gasket. Install oil return tube. Torque fasteners to 12 Nm (105 inch lbs.). Make sure heat shield for oil return line is properly installed (Fig. 8).
11. Install turbocharger elbow support bracket (Fig. 11).
12. Install turbocharger to charge air cooler hose assembly (Fig. 10).
13. Install catalytic converter with new gasket.
14. Install fasteners securing catalytic converter to exhaust manifold (Fig. 9). Torque fasteners to 28 Nm (250 inch lbs.).
15. Connect downstream oxygen sensor.
16. Connect exhaust extension pipe to catalytic converter.
17. Install power steering cooler fasteners.
18. Lower vehicle.





19. Connect oil supply line at turbocharger. Install NEW washers (Fig. 14). Torque banjo fitting bolt to 37 Nm (27 ft. lbs.).

NOTE: The lower turbocharger heat shield tabs must over lap the upper heat shield tabs to prevent fatiguing and early failure.

20. Install turbocharger lower heat shield. Torque upper and lower heat shield fasteners to 28 Nm (250 inch lbs.) (Fig. 11).
21. Connect vacuum hoses to turbocharger.
22. Connect upstream oxygen sensor.
23. Install ignition coil. Connect electrical connector.
24. Install electrical connector into bracket (Fig. 7).
25. Install clean air hose (Fig. 10).
26. Fill cooling system.
27. Change oil and filter.
28. Install battery.
29. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
30. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.