Turbocharger: Service and Repair

Exhaust Manifold And Turbocharger Part 1:

Exhaust Manifold And Turbocharger Part 2:

Use special tool MD998770 to remove the heated oxygen sensor (front).

<>

TURBOCHARGER OIL FEED PIPE REMOVAL

CAUTION: Take care not to allow foreign objects to get into the oil passage hole of the turbocharger assembly after the turbocharger oil feed pipe is removed.

INSTALLATION SERVICE POINTS

>>A<< TURBOCHARGER ASSEMBLY INSTALLATION

1. Clean the oil pipe and water pipe fitting, the inside of eye bolts, and individual pipe for clogs.

CAUTION: Take care not to allow foreign objects to get into the turbocharger assembly.

2. Clean or use compressed air to remove any carbon particles stuck to the oil passage of the turbocharger assembly.
3. Refill new engine oil at the oil feed pipe fitting hole of the turbocharger assembly.

>>B<< AIR OUTLET FITTING GASKET INSTALLATION

Install the gasket so that its protrusion faces in the direction shown in the illustration.

>>C<< TURBOCHARGER OIL RETURN PIPE GASKET INSTALLATION

Install the gasket so that its protrusion faces in the direction shown in the illustration.

>>D<< HEATED OXYGEN SENSOR (FRONT) INSTALLATION

Use special tool MD998770 to install the heated oxygen sensor (front).

INSPECTION
Check the following points; replace the part if a problem is found.

EXHAUST MANIFOLD CHECK
1. Check for damage or cracking of any part.
2. Using a straight edge and a feeler gauge, check for distortion of the cylinder head installation surface.

Standard value: 0.15 mm (0.006 inch) or less

Limit: 0.20 mm (0.008 inch)

TURBOCHARGER ASSEMBLY CHECK

1. Visually check the turbine wheel and the compressor wheel for cracking or other damage.
2. Check whether the turbine wheel and the compressor wheel can be easily turned by hand.
3. Check for oil leakage from the turbocharger assembly.
4. Check whether or not the turbocharger wastegate regulating valve remains open. If any problem is found, replace the part after disassembly.

EXHAUST MANIFOLD AND TURBOCHARGER

DISASSEMBLY AND REASSEMBLY

Exhaust Manifold And Turbocharger:

DISASSEMBLY SERVICE POINTS

<> SNAP RING REMOVAL

CAUTION: Hold the snap ring with your fingers during its removal to prevent it from springing away. Remove the compressor cover retaining snap ring using a snap ring pliers.

<> CARTRIDGE ASSEMBLY REMOVAL

CAUTION: The cartridge assembly may be stuck on the compressor cover by the O-ring.

Loosen the cartridge assembly before removal by lightly tapping the compressor cover all around with a plastic hammer.

CLEANING
1. Use a clean washing solvent available on the market to wash the turbocharger components.
2. Use a plastic scraper or bristle brush for cleaning aluminum parts.

REASSEMBLY SERVICE POINTS

>>A<< O-RING INSTALLATION

CAUTION: Be careful not to damage the O-ring during installation. Damaged O-ring could cause leaks.

Smear engine oil on the inside surface of a new O-ring and fit it in the groove of the cartridge assembly.

>>B<< CARTRIDGE ASSEMBLY INSTALLATION

1. Smear engine oil on the inside of the O-ring fitted on the cartridge assembly.

CAUTION: Be careful not to damage the vanes of the cartridge assembly when installing the cartridge assembly onto the compressor cover.

2. Install the cartridge assembly onto the compressor cover aligning the dowel pin with its hole.

>>C<< SNAP RING INSTALLATION

CAUTION: Install the snap ring with its chamfer facing up.

Place the set of cartridge assembly and compressor cover upright on the compressor cover and install the snap ring in position

>>D<< TURBINE HOUSING INSTALLATION

CAUTION:
- Be careful not to damage the vanes of the cartridge assembly when installing the turbine housing.
- Pay attention to alignment of the turbine housing.

Assemble the set of compressor cover and cartridge assembly with the turbine housing while aligning the dowel pin with its hole.

CHECK (DISASSEMBLY AND REASSEMBLY)

TURBINE HOUSING

1. Check the turbine housing for turbine wheel contact marks, cracks due to overheating, pitting, deformation, or other kinds of damage. Replace the turbine housing if any crack is found.
2. Operate the waste gate valve lever by hand to check that the valve can be opened and closed smoothly.

COMPRESSOR COVER
Check the compressor cover for compressor wheel contact marks or other damage.

CARTRIDGE ASSEMBLY

1. Check the vanes of the turbine and compressor wheel for deformation, damage on edges and other surfaces, corrosion, contact marks on back surfaces, and any other defect. Replace the cartridge assembly if any of the defects is present in the vanes.
2. Check the oil and coolant passages for clogging and damage.

WASTE GATE ACTUATOR

CAUTION: Never apply a pressure greater than 113.3 kPa. Applying a higher pressure could result in a broken diaphragm.

Check that the rod moves when a pressure of the standard value is applied to the actuator using a tester.

Standard value: 100 kPa