Turbocharger: Service and Repair

Turbocharger Replacement

Special Tools

EN-49942 - Holding Wrench

For equivalent regional tools, refer to Special Tools Tools and Equipment.

Removal Procedure

1. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.

2. Drain the cooling system. Refer to Cooling System Draining and Filling Cooling System Draining and Filling.

3. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement.

4. Disconnect the positive crankcase ventilation pipe from turbocharger. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement Service and Repair.

5. Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement (LUV) Exhaust Manifold Heat Shield ReplacementExhaust Manifold Heat Shield Replacement (LUW) Exhaust Manifold Heat Shield Replacement.





6. Disconnect the turbocharger wastegate regulator solenoid valve wiring harness connector (1) and unclip wiring harness from retainer clip (2).





7. Remove the turbocharger oil feed pipe hollow screw (4).

8. Remove and DISCARD the 2 seal rings (1) and (3).

9. Remove the turbocharger oil feed pipe bolt (5).

Note:
Close the screw bore in the turbocharger in order to avoid contamination.

10. Remove the turbocharger oil feed pipe (2).

11. Loosen the turbocharger coolant return hose clamp and remove the turbocharger coolant return hose (6) from the oil cooler inlet pipe.

12. Remove the turbocharger coolant return pipe bolt (7).

13. Remove the charge air cooler inlet air hose from the turbocharger. Refer to Charge Air Cooler Inlet Air Hose Replacement Charge Air Cooler Inlet Air Hose Replacement.





14. Install the EN-49942 - holding wrench (2) to the turbocharger coolant feed pipe. Guide a ratchet wrench (1) along with an extension through EN-49942 - holding wrench to the turbocharger coolant feed pipe hollow screw.





Note:
EN-49942 - holding wrench (2) should be installed to turbocharger coolant feed pipe as shown. The holding wrench should be installed to avoid twist of the turbocharger coolant feed pipe during the loosening procedure.

15. Loosen the turbocharger coolant feed pipe hollow screw with ratchet wrench and extension (1).

16. Remove the turbocharger coolant feed pipe hollow screw.

17. Remove and DISCARD the 2 seal rings.

18. Remove the three way warm catalytic converter. Refer to Catalytic Converter Replacement (LUV) Catalytic Converter Replacement.





19. Remove the 2 turbocharger oil return pipe bolts (1) from turbocharger.

20. Remove the turbocharger oil return pipe from the turbocharger.

21. Remove and DISCARD the gasket.





22. Remove and DISCARD the 8 turbocharger nuts (1).





23. Remove the turbocharger assembly (1).

24. Remove and DISCARD the turbocharger gasket (2).

25. Remove the assembly parts from the turbocharger as necessary. Refer to Turbocharger Disassemble Service and Repair.

26. If the turbocharger is being reused, refer to Turbocharger Cleaning and Inspection Service and Repair.

Installation Procedure

1. Install the assembly parts to the turbocharger as necessary. Refer to Turbocharger Assemble Service and Repair.

2. Clean the sealing surfaces.





3. Install a NEW turbocharger gasket.

4. Install the turbocharger assembly (1).





5. Install the 8 NEW turbocharger nuts (1).





Caution:
Refer to Fastener Caution Fastener Caution.

Caution:
Refer to Torque-to-Yield Fastener Caution Torque-to-Yield Fastener Caution.

6. Tighten the 8 turbocharger nuts in a sequence as shown to 8 Nm (71 lb in).

7. Repeat the tightening procedure to ensure a proper fastening of the turbocharger nuts.





8. Install a NEW gasket and the 2 turbocharger oil return pipe bolts (1) and tighten to 8 Nm (71 lb in).

9. Install the three way warm up catalytic converter. Refer to Catalytic Converter Replacement (LUV) Catalytic Converter Replacement.





10. Install the turbocharger coolant feed pipe to the engine block. Use the following procedure:

* Install a NEW seal ring (3) to the turbocharger coolant feed pipe hollow screw (4).

* Install the turbocharger coolant feed pipe hollow screw along with the seal ring to the turbocharger coolant feed pipe (2).

* Install a NEW seal ring (1) to the turbocharger coolant feed pipe hollow screw.

* Install the turbocharger coolant feed pipe hollow screw along with the turbocharger coolant feed pipe and the 2 seal rings to the engine.





Note:
The EN-49942 - holding wrench should be installed in a perpendicular position as shown to ensure a proper installation position of the turbocharger coolant feed pipe.

11. Install the EN-49942 - holding wrench(2) to the turbocharger coolant feed pipe. Guide a ratchet wrench (1) along with an extension through EN-49942 - holding wrench to the turbocharger coolant feed pipe hollow screw.





Note:
EN-49942 - holding wrench(2) should be installed to the turbocharger coolant feed pipe as shown. The holding wrench should be installed to avoid twist of the turbocharger coolant feed pipe during the fastening procedure.

12. Tighten the turbocharger coolant feed pipe hollow screw with ratchet wrench and extension (1) to 30 Nm (22 lb ft).

13. Install the charge air cooler inlet air hose to the turbocharger. Refer to Charge Air Cooler Inlet Air Hose Replacement Charge Air Cooler Inlet Air Hose Replacement.





14. Install the turbocharger coolant return pipe bolt (7) and tighten to 8 Nm (71 lb in).

15. Install the turbocharger coolant return hose (6) to the oil cooler inlet pipe.

16. Install the turbocharger coolant return hose clamp.

17. Install the turbocharger oil feed pipe (2) to the oil cooler and the turbocharger.

18. Install the turbocharger oil feed pipe bolt (5).

19. Install the turbocharger oil feed pipe hollow screw (4) along with the 2 NEW seal rings (1) and (3) and tighten to 30 Nm (22 lb ft).

20. Tighten the turbocharger oil feed pipe bolt to 10 Nm (89 lb in).





21. Connect the turbocharger wastegate regulator solenoid valve wiring harness connector (1) and clip in wiring harness to retainer clip (2).

22. Install the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement (LUV) Exhaust Manifold Heat Shield ReplacementExhaust Manifold Heat Shield Replacement (LUW) Exhaust Manifold Heat Shield Replacement.

23. Connect the positive crankcase ventilation pipe to the turbocharger. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement Service and Repair.

24. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement.

25. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.

26. Fill the cooling system. Refer to Cooling System Draining and Filling Cooling System Draining and Filling.