Removal and Installation

REMOVAL OF TURBOCHARGER
1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY
2. DRAIN COOLANT

3. REMOVE NO.4 AIR CLEANER PIPE WITH NO.1 AND NO.2 AIR CLEANER HOSE

4. REMOVE NO.7 AIR CLEANER HOSE WITH AIR FLOW METER AND AIR CLEANER CAP
(a) Disconnect the three air hoses and PCV hose.
(b) Disconnect the air flow meter connector.
(c) Disconnect the PS air hose.

(d) Loosen the clamps and remove the bolt.
(e) Remove the No.2 air cleaner hose with air flow meter and air cleaner cap.

5. REMOVE TURBO HEAT INSULATOR
(a) Disconnect the oxygen sensor connector.
(b) Remove the three nuts, washer and turbo heat insulator.

6. REMOVE OIL DIPSTICK GUIDE
(a) Remove the oil dipstick.
(b) Remove the bolt and oil dipstick guide.
(c) Remove the 0-ring from the oil dipstick guide.

7. REMOVE NO.1 AIR CLEANER PIPE WITH NO.6 AIR CLEANER HOSE
(a) Loosen the No.5 and No.6 air cleaner hose clamps.

(b) Remove the No.1 air cleaner pipe mounting bolt.
(c) Remove the No.1 air cleaner pipe with No.6 air cleaner hose.

8. DISCONNECT FRONT EXHAUST PIPE
(a) Remove the three nuts.

(b) Remove the front exhaust pipe clamp.
(c) Disconnect the front exhaust pipe from the exhaust manifold.
(d) Remove the gasket.

9. REMOVE OIL OUTLET PIPE MOUNTING NUTS
10. REMOVE OIL INLET PIPE MOUNTING UNION BOLT

11. REMOVE TURBOCHARGER STAY

12. REMOVE NO.2 TURBOCHARGER STAY

13. DISCONNECT NO.1 TURBO WATER HOSE FROM WATER OUTLET HOUSING

14. DISCONNECT NO.2 WATER BY-PASS PIPE UNION
Remove the union bolt and gaskets.

15. REMOVE TURBOCHARGER
Remove the tour nuts, turbocharger and gasket.

16. REMOVE NO.1 TURBO WATER PIPE
Remove the two nuts, No.1 turbo water pipe and gasket.

17. REMOVE OIL PIPE
Remove the two nuts, oil pipe and gasket.

18. REMOVE TURBINE OUTLET ELBOW
Remove the four nuts, turbine outlet elbow and gasket.

INSPECTION OF TURBOCHARGER
1. INSPECT IMPELLER WHEEL ROTATION
Grasp the edge of the turbine wheel and turn it. Check that the impeller wheel turns smoothly.
If the impeller wheel does not turn or if it turns with a drag, replace the turbocharger assembly.

2. INSPECT AXIAL PLAY OF SHAFT BEARING
Insert a dial gauge into the intake side, hold the turbine wheel edge by and check the axial play.
Standard clearance: 0.13 mm (0.0051 in.) or less
If not within specification, replace the turbocharger assembly.

INSTALLATION OF TURBOCHARGER

CAUTION:After replacing the turbocharger assembly, pour approx. 20 cc (1.2 cu in.) of new oil into the oil inlet and turn the impeller wheel by hand to splash oil on the bearing.

1. IN STALL TURBINE OUTLET ELBOW
Install a new gasket and the turbine outlet elbow with the four nuts.
Torque: 530 kg-cm (38 ft-lb, 52 N.m)

2. INSTALL OIL PIPE
Install a new gasket and the oil pipe with the two nuts.
Torque: 130 kg-cm (9 ft-lb, 13 N.m)

3. INSTALL TURBO WATER PIPE
Install a new gasket and the water pipe with two nuts
Torque: 75 kg-cm (5 ft-lb, 7.4 N.m)

4. INSTALL TURBOCHARGER
(a) Face the new gasket so the protrusion is facing the rear and install on the exhaust manifold.
(b) Place a new gasket on the return hole of the cylinder block.

(c) Install the turbocharger through the turbocharger stud bolts and oil pipe stud bolts.
(d) Temporarily install the four nuts holding the exhaust manifold and turbocharger.
(e) Temporarily install the oil pipe flange nut.
(f) Temporarily install the union bolt with two new gasket.

(g) Torque the turbocharger mounting nuts.
Torque: 450 kg-cm (33 ft-lb, 44 N.m)
(h) Torque the oil pipe union bolt and flange nuts.
Torque: Bolt 350 kg-cm (25 ft-lb, 34 N.m)
Nut 130 kg-cm (9 ft-lb, 13 N.m)

5. CONNECT NO.2 WATER BY-PASS PIPE UNION
Connect the No.2 water by-pass union with union bolt and new gasket.

6. CONNECT NO.1 TURBO WATER HOSE TO WATER OUTLET HOUSING

7. INSTALL NO.2 TURBOCHARGER STAY

8. INSTALL TURBOCHARGER STAY
Torque:
To turbocharger 810 kg-cm (59 ft-lb, 79 N.m)
To engine mounting bracket 590 kg-cm (43 ft-lb, 58 N.m)

9. CONNECT OIL INLET PIPE WITH NEW GASKET
10. INSTALL AND TORQUE OIL OUTLET PIPE MOUNTING NUTS

11. CONNECT FRONT EXHAUST PIPE
(a) Install a new gasket to the front exhaust pipe.
(b) Install the front exhaust pipe to the exhaust manifold with new three nuts.

12. INSTALL NO.1 AIR CLEANER PIPE WITH NO.6 AIR CLEANER HOSE
(a) Install the No.1 air cleaner pipe with No.6 air cleaner hose to the No.5 air cleaner hose and turbocharger.
(b) Connect the No.1 air cleaner pipe to bracket with the bolt.
Torque: 130 kg-cm (9 ft-lb, 13 N.m)

13. INSTALL OIL DIPSTICK GUIDE
(a) Install a new 0-ring to the oil dipstick guide.
(b) Insert the oil dipstick guide to the No.2 oil.
(c) Connect the oil dipstick guide to the turbocharger with the bolt.
(d) Install the oil dipstick.

14. INSTALL TURBO HEAT INSULATOR
(a) Install the turbo heat insulator and washer with the three nuts.
(b) Connect the oxygen sensor connector.

15. INSTALL NO.7 AIR CLEANER HOSE WITH AIR FLOW METER AND AIR CLEANER CAP
(a) Install the No.2 air cleaner hose with air flow meter and air cleaner clamp.

(b) Install the bolt and tighten the clamp.
(c) Connect the PS air hose.
(d) Connect the air flow meter connector.
(e) Connect the PCV hose and three air hoses.

16. INSTALL NO.4 AIR CLEANER PIPE WITH NO.1 AND NO.2 AIR CLEANER HOSE
17. FILL WITH COOLANT
18. CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY
19. START ENGINE AND CHECK FOR LEAKS