Turbocharger: Service and Repair

TURBOCHARGER REPLACEMENT





Remove:
^ Heat shield over exhaust manifold.





Remove Components from Turbocharger
^ Undo upper charge air pipe with lower rubber hose, from Turbocharger (TC) and move to one side.
^ Remove fresh air hose.
^ Remove inner heat shield.
^ Undo upper TC return coolant pipe, clamp coolant hose with clamping pliers and move pipe/hose to one side.
^ Undo inlet oil pipe nipple.
^ Raise car.





Remove:
^ Clamp between pipes.
^ Oil return pipe.
^ Exhaust pipe bracket screw.
^ Exhaust pipe-TC nut.
^ Exhaust manifold-TC nuts.
^ Clamp coolant inlet hose with pliers.
^ Lower car.





Undo Turbocharger
^ Remove exhaust pipe-TC nuts.
^ Undo inlet-coolant pipe.
^ Remove TC-exhaust manifold nuts.





Disconnect Hoses for:
^ Boost pressure (red).
^ Bypass valve (white).
^ Pressure regulator (yellow).

Remove:
^ Turbocharger.
^ Old pin screws from exhaust manifold.





Install:
^ New pin screws (if missing) tighten to 25 Nm (18.5 ft lb).
^ Hoses as marked
^ Both upper exhaust manifold nuts, and tighten somewhat.
^ Raise car

NOTE: When installing pin screws, always use Loctite (strong), P/N 1161076-5.





Install:
^ Lower exhaust manifold nuts, tighten to 25 Nm (18.5 ft lb).





Tighten Turbocharger
^ Tighten upper exhaust manifold nuts to 25 Nm (18.5 ft lb).
^ Tighten exhaust manifold-TC, tighten all nuts to 30 Nm (22 ft lb), check that surfaces are parallel at the same time.
^ Raise car.





Install lower oil pipe
^ Install oil pipe (grease 0-ring).
^ Install exhaust pipe bracket screw.
^ Lower car.





Install:
^ Oil inlet pipe.
^ Inlet and outlet coolant pipes (remove clamping pliers).
^ Fresh air hose.
^ Inner heat shield.
^ Upper charge air pipe.
^ Outer heat shield.
^ Raise car.

NOTE: Replace copper coolant pipe and upper oil pipe washers.





Install Clamp Between Pipes
^ Remove clamping pliers from coolant return hose.
^ Lower car.

Carry Out Function Test
^ Check boost pressure.
^ Check oil and coolant levels.

NOTE: DTC 3-5-2 may be posted after the TC has been replaced, reset as needed.