7.1 Removing and Installing Turbocharger

Fig. 7-2 shows the turbocharger and related components.

Fig. 7-2.

Exploded view of turbocharger and related components.

To remove:

1.	Disconnect the battery negative (-) terminal. On cars with automatic transmission, remove the starter as described in ELECTRICAL SYSTEM.

2.	Disconnect the turbocharger exhaust pipe from the turbocharger by removing the four mounting nuts. Remove the gasket.

3.	Disconnect the oil supply line and its bracket from the top of the turbocharger. Plug the oil hole in the turbocharger, and seal the end of the detached oil line.

4.	Loosen the clamps and remove the air ducts that connect the air cleaner to the turbocharger and the turbocharger to the intake manifold.

5.	Disconnect the oil return line from the engine oil pan. Plug the end of the disconnected line and the connection on the oil pan.

6.	Working from under the vehicle, use a 12mm, 12-point socket wrench to remove the four polygon-head mounting bolts shown in Fig. 7-3 that hold the turbocharger to the exhaust manifold. Remove the turbocharger.

Fig. 7-3.

Polygon-head bolts (arrows) to be removed.

To install:

1.	Loosely connect the turbocharger with oil return line to the turbocharger exhaust pipe. Use a new gasket. Thread the mounting nuts on only finger tight.

2.	Thoroughly clean the mating surfaces between the turbocharger and the exhaust manifold, and make sure that they are undamaged. This is important as no gasket is used.

3.	Apply a high-temperature anti-seize compound to the threads of the polygon-head bolts. Connect the turbocharger to the exhaust manifold, evenly torquing the four bolts to 45 Nm (33 ft. lb.).

4.	Torque the turbocharger exhaust pipe nuts to 25 Nm (18 ft. lb.).

5.	Reconnect the oil return line to the engine oil pan. Torque the union to 30 Nm (22 ft. lb.).

6.	Reinstall the intake air ducts. Replace any that is deformed or cracked. On cars with automatic transmission, reinstall the starter, as described in ELECTRICAL SYSTEM

7.	Pre-lubricate the turbocharger by pouring clean engine oil into the oil hole, filling it as full as possible. Reconnect the oil supply line. Torque the oil supply line unions to 30 Nm (22 ft. lb.).

8.	Start the engine and let it idle for at least one minute prior to any higher speed operation. Check for oil leaks or exhaust leaks and make any necessary repairs before returning the car to use.