Turbocharger: Service and Repair

Removal





1. Remove the air intake pipe and the air intake hose.
2. Remove the water return and feed hose.





3. Disconnect the oil feed pipe and the oil drain pipe connector hose.





4. Remove the turbo charger discharge pipe and the turbo charger discharge pipe bracket.
5. Remove the turbo charger to exhaust manifold bolt, and remove the turbo charger as an assembly.

Disassembly





1. Disconnect the boost hose from the waste gate actuator
2. Remove the retaining ring at waste gate valve lever.
3. Remove the waste gate actuator mounting bolts to remove the actuator.

CAUTION: Make sure that the mating mark on turbine housing and center housing & rotating assembly are aligned for reassembling.





4. Remove the bolt that holds the clamp on the turbine housing then remove the turbine housing with the waste gate valve.

CAUTION: Never attempt to adjust the waste gate valve and actuator rod length.





5. Place the compressor cover assembly on the floor with its end surface down and remove the snap ring with pliers.

CAUTION: During removal, hold the snap ring so that it does not fly out.

6. Remove the center housing rotating assembly

INSPECTION

Turbocharger

1. Inspect the cast-iron turbine housing for damage, cracks, or evidence of contact between the turbine blades and the housing.
2. Manually open and close the waste gate valve to make sure it operates freely.
3. Inspect the turbine and compressor wheels for wear, damage, bent or broken blades.
4. Inspect the oil passage in the cartridge for signs of deposits or blockage.
5. Clean the inlet section of the compressor cover with a rag. Inspect it for signs of contact with the compressor turbine. If worn, replace it.

Waste gate actuator

1. Leak-test the waste gate valve actuator with a hand pump. Replace the actuator if leakage indicates a ruptured diaphragm.
2. Check the rod to see that it is not bent or binding so as to require replacement.

Oil pipe and oil return pipe

1. Inspect the oil pipe ends for evidence of carbon-like deposits. If present, replace the oil pipe.
2. Inspect the oil return pipe to make sure it is clear. If blocked, clean it out.

REASSEMBLY

1. Clean the inside of turbine housing and compressor cover by scrubbing with a bristle brush, blowing compressed air and wiping with a clean cloth.





2. Apply a thin coat of engine oil to the inside surface of the new 0-ring and install it in the cartridge assembly groove.





3. Apply a thin coat of engine oil to the outer periphery of the 0-ring having been installed on center housing & rotating assembly, then place the center housing & rotating assembly in the compressor cover.

CAUTION: Use care not to damage the vanes when installing the center housing & rotating assembly in compressor cover.





4. Place the compressor cover with center housing & rotating assembly inside on floor with its end surface down and install the retaining ring.
5. Combine the compressor cover and center housing & rotating assembly with the turbine housing.

CAUTION: Do not damage the center housing & rotating assembly vanes.





6. Install the turbine housing bolt with clamps.
7. Install the waste gate actuator to the compressor cover.

Tightening torque
Waste gate actuator bolt: 20 - 24 Nm(14 - 17 ft lb)
Turbine housing fitting bolt: 2.8 - 5.6 Nm(2 - 4 ft lb)

8. Install the retaining ring to the waste gate valve lever.
9. Connect the boost hose.

INSTALLATION

- Perform installation in reverse procedure of removal, paying special attention to the following items:





1. Torque all parts to specifications shown in the component illustration.
2. Before installing oil pipe eye joint bolt (at top of the turbocharger), pour clean engine oil into the turbocharger.
3. Make sure that the oil and air hoses, etc. are properly installed and securely clamped.
4. Do not reuse a heat-damaged, corroded or deformed exhaust manifold gasket or turbocharger gasket.