Turbocharger: Service and Repair

TURBO I MODELS 1984-87

1. Disconnect battery ground cable and drain cooling system.
2. Raise and support front of vehicle.
3. Disconnect exhaust pipe at articulated joint and the wire connector at oxygen sensor.
4. Remove turbocharger housing to block support bracket.
5. Loosen oil drain back tube connector hose clamps and move tube down on block nipple.
6. Disconnect turbocharger coolant tube nut at block outlet below steering pump bracket and disconnect coolant tube at tube support bracket.
7. Lower vehicle.
8. Remove air cleaner assembly, including throttle body adapter, hose, and air cleaner box with block support bracket.
9. Disconnect accelerator linkage, throttle body electrical connectors and vacuum hoses.
10. Loosen throttle body to turbocharger inlet hose clamps.
11. Remove 3 throttle body to intake manifold attaching screws, then the throttle body.
12. Loosen turbocharger discharge hose end clamps. Remove discharge hose end clamps only. Center hose clamp retains de-swirler and must not be removed.
13. Relocate fuel rail by removing 4 bracket screws from intake manifold and the 2 bracket to heat shield retaining clips, then lift and secure fuel rail with injectors, wiring harness, and fuel lines intact, up out of the way.
14. Remove 3 heat shield to intake manifold attaching screws, then the heat shield.
15. Disconnect coolant return tube and hose assembly from turbocharger housing to water box, then remove tube support bracket from cylinder head and remove tube and hose assembly.
16. Disconnect oil feed line from oil sending unit hex tee and turbocharger bearing housing, then remove support bracket.
17. Remove 4 turbocharger to exhaust manifold attaching nuts.
18. Remove turbocharger assembly by lifting it off exhaust manifold studs while pushing downward toward passenger side of unit, then lift turbocharger up and out of engine compartment.
19. Reverse procedure to install, noting the following:
a. Position turbocharger assembly on exhaust manifold studs, ensuring turbocharger discharge tube is properly positioned between intake manifold and turbocharger.
b. Apply suitable anti-seize compound to threads of exhaust manifold studs, then install attaching nuts and torque to 40 ft. lbs.
c. Torque oil feed line tube nuts to 125 inch lbs., then install and tighten support bracket screw.
d. Torque 3 heat shield to intake manifold attaching screws to 105 inch lbs.
e. Torque coolant tube nuts to 30 ft. lbs., then install bracket screw.
f. Torque 4 fuel rail bracket to intake manifold retaining screws to 250 inch lbs. and install shield to bracket clips.
g. Torque discharge tube hose clamp to 35 inch lbs.
h. Torque 3 throttle body to intake manifold attaching screws to 250 inch lbs.
i. Torque throttle body hose clamps to 35 inch lbs.
j. Connect accelerator linkage, electrical connector and vacuum hoses.
k. Torque 2 hose adapter to throttle body attaching screws to 55 inch lbs. and the air cleaner box support screws to 40 ft. lbs.
l. Torque coolant tube nut to block connector to 30 ft. lbs.
m. Position oil drain back hose and torque clamps to 30 inch lbs.
n. Install turbocharger to block support bracket and install screws finger tight. Torque block screw to 40 ft. lbs., then torque turbocharger housing screw to 20 ft. lbs.
o. Torque exhaust system articulated joint shoulder bolts to 250 inch lbs.
p. Fill cooling system, then connect battery ground cable.




TURBO II MODELS 1984-87
Whenever the turbocharger on this engine requires removal, the intake and exhaust manifolds must also be removed for servicing.
1. Disconnect battery ground cable, then drain cooling system.
2. Remove air cleaner assembly and upper intake manifold plenum to cylinder head support bracket.
3. Separate throttle body from intake manifold, then disconnect EGR tube from valve, PCV valve, MAP sensor, brake booster vacuum supply hose and charge temperature sensor electrical connector.
4. Remove starter.
5. Working from below vehicle, remove seven upper intake intake manifold plenum to lower intake manifold attaching screws.
6. With car lowered to ground, remove upper intake manifold plenum and gasket. Do not allow any dirt to enter intake runners.
7. Remove cowl mounted heat shield, then position fuel rail aside.
8. Disconnect turbocharger bearing oil feed line at oil sending unit hex and coolant tube at water box, then oil and water lines from support bracket mounted on cylinder head.
9. Remove right intermediate shaft, bearing support bracket and outer driveshaft assembly.
10. Remove turbocharger to engine block support bracket attaching screws, then the bracket.
11. Disconnect exhaust system at articulated joint and electrical connector at oxygen sensor.
12. Loosen clamps at oil drain back tube connector, then move tube down on black nipple.
13. Disconnect coolant (pressure) tube nut from engine block and tube support bracket.
14. Remove turbocharger to exhaust manifold attaching bolts, then the turbocharger assembly. When removing turbocharger, use caution not to damage oil or coolant lines.
15. Remove intake manifold runner to cylinder head attaching bolts and washers, then the intake runner.
16. Remove exhaust manifold to cylinder head attaching nuts, then the exhaust manifold.
17. Discard gaskets and clean mating surfaces. Inspect manifolds for cracks or distortion.
18. Using suitable feeler gauge and straightedge, check gasket surfaces for flatness. Flatness must be within .006 inch per foot of manifold length.
19. Install replacement intake/exhaust manifold gasket. Do not apply sealer.
20. Position intake manifold runner on cylinder head and install attaching bolts and washers finger tight. Starting from center bolt and progressing out in either direction, torque attaching bolts to 200 inch lbs.
21. Position exhaust manifold on cylinder head and install attaching nuts finger tight. Starting from center bolt and progressing out in either direction, torque attaching bolts to 200 inch lbs.
22. Install fuel rail and cowl mounted heat shield.
23. Install replacement gasket on intake manifold runner, then position upper intake manifold plenum on gasket. Install and tighten attaching bolts to 200 inch lbs.
24. Install upper intake manifold plenum to cylinder head support bracket. Torque attaching bolts to 40 ft. lbs.
25. Position turbocharger on exhaust manifold, then apply suitable anti-seize compound to threads. Install nuts and torque to 40 ft. lbs.
26. Connect coolant tube nut to engine engine block. Torque to 30 ft. lbs.
27. Connect oil drain back hose. Torque clamps to 30 inch lbs.
28. Position turbocharger to cylinder head support bracket and install attaching bolts finger tight. First, torque block bolt to 40 ft. lbs., then turbocharger bolt to 20 ft. lbs.
29. Install exhaust pipe. Torque shoulder bolts to 250 inch lbs.
30. Install driveshaft assembly and starter.
31. Install oil feed line on sending unit hex. Torque tube nut to 125 inch lbs.
32. Install EGR tube to EGR valve. Torque tube nut to 60 ft. lbs.
33. Install PCV valve, MAP sensor, brake booster vacuum supply hose and charge temperature sensor electrical connector.
34. Fill cooling system, then connect battery.