Turbocharger: Service and Repair

1. Loosen A/C compressor belt tensioner, then remove A/C compressor drive belt.
2. Disconnect upper pipe coupling on oil cooler, then remove clips attaching pipe to radiator.
3. Remove A/C compressor mounting bolts, then insert piece of sheet metal to protect oil cooler and position A/C compressor aside.
4. Disconnect solenoid valve electrical connector, then remove solenoid valve from mounting on radiator.
5. Disconnect radiator cooling fan electrical connector, then remove mounting bolts and radiator cooling fan.
6. Disconnect air mass meter electrical connector and remove clips securing air mass meter to air cleaner cover, then pull rubber socket connector off turbocharger and position air mass meter aside.
7. Disconnect pressure pipe from turbocharger.
8. Remove bolts securing oil pipe to turbocharger, then unbolt clutch slave cylinder and remove clip securing oil pipe to cylinder head.
9. Disconnect oil pipe banjo coupling from engine block, then remove clip on intake manifold.
10. Disconnect exhaust pipe from turbocharger.
11. Disconnect exhaust pipe front rubber hangers.
12. Remove support bracket between oil pan and turbocharger.
13. Remove attaching bolts for oil return pipe at engineblock. Cover exposed hole to prevent nuts or washers from exhaust manifoldentering engine during removal.
14. Remove nuts and washers securing exhaust manifold to cylinder head.
15. Lower exhaust manifold until clear of studs, then remove exhaust manifold and turbocharger unit as an assembly.
16. Mount assembly in vise and remove nuts attaching turbocharger and exhaust manifold.
17. Separate turbocharger from exhaust manifold.
18. Reverse procedure to install, noting the following:
a. Install new locknuts attaching turbocharger to exhaust manifold with locking flanges turned inward, then tighten to specifications.
b. Tighten exhaust manifold nuts to specifications.
c. Adjust A/C drive belt tension.