Turbocharger: Service and Repair

Turbocharged engine components. Turbo I & II models.:

TURBO I & II MODELS
Intake and exhaust manifolds use a one piece gasket. Service procedures requiring removal and installation (of either) must include both manifolds.
1. Disconnect battery ground cable, then drain cooling system and remove air cleaner assembly.
2. Separate throttle body from intake manifold; then disconnect PCV and vacuum hoses, accelerator linkage and (Turbo II only) charge temperature sensor.
3. Remove fuel rail assembly.
4. Remove front engine mount through bolt and rotate engine forward away from cowl.
5. Remove coolant line and fitting from turbocharger assembly.
6. Disconnect oil feed line from turbocharger housing and and remove waste gate rod to gate retaining clip.
7. Remove three (two upper and one lower, driver's side) turbocharger to exhaust manifold retaining nuts. Disconnect oxygen sensor lead wire and vacuum lines.
8. Raise and support vehicle. Working from below, remove right front wheel and right side drive shaft.
9. Remove turbocharger to block support bracket.
10. Remove oil drain back fitting and hose from turbocharger housing.
11. Remove the remaining turbocharger to exhaust manifold retaining nut, disconnect articulated exhaust pipe joint from turbocharger housing, then remove lower coolant line and turbocharger inlet fitting.
12. Lift turbocharger off exhaust manifold mounting studs and lower down and out of vehicle.
13. Remove 8 intake manifold screws and washers, then the intake manifold.
14. Remove 8 exhaust manifold retaining nuts, then the exhaust manifold.
15. Reverse procedure to install. Note the following:
a. Torque 8 intake manifold retaining screws and 8 exhaust manifold retaining nuts to 200 inch lbs. Start at center and progress outward.
b. Position turbocharger assembly on exhaust manifold and apply suitable anti sieze compound to threads of exhaust manifold studs, then install lower passenger side retaining nut. Torque to 40 ft. lbs.
c. Apply antisieze compound to lower (inlet) coolant line fitting, install fitting into turbocharger housing, then install lower coolant line.
d. Install oil drain back tube and fitting to turbocharger housing.
e. Install turbocharger to block support bracket, installing screws finger tight. Torque block screw to 40 ft. lbs. first, then torque screw to turbocharger housing to 20 ft. lbs.
f. Reposition exhaust pipe, torquing articulated shoulder bolts to 250 inch lbs.
g. Install right driveshaft and wheel, then lower vehicle.
h. Working from above, install 3 turbocharger to exhaust manifold retaining nuts. Torque to 40 ft. lbs.
i. Reconnect oxygen sensor electrical connection and vacuum lines, then install waste gate rod to gate retaining clip.
j. Attach oil feed line to turbocharger bearing housing. Torque fitting to 125 inch lbs.
k. Apply thread sealant to water box/turbocharger, return coolant line end fittings, install line and torque fittings to 30 ft. lbs.
l. Align front engine mount in crossmember bracket, then install through bolt and torque to 40 ft. lbs.
m. Install fuel injector rail assembly and throttle body. Reconnect accelerator linkage, vacuum vapor harness, PCV and brake booster hoses, and charge temperature sensor (Turbo II). Install air cleaner, refill cooling system and reconnect battery.