Turbocharger – Remove operations


Removal Procedure (Side Mounted Turbochargers)

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Dispose of all fluids according to local regulations and mandates.
Disconnect the air hose for the turbocharger inlet and for the turbocharger outlet. If the turbocharger has a remote wastegate solenoid, disconnect the hose to the solenoid from the turbocharger. Disconnect the exhaust pipe.
If the turbocharger has an exhaust elbow, remove the exhaust elbow.


Follow Steps to remove the tube assembly (4) for the oil feed.
Remove the setscrew (5).
Remove the banjo bolt (1) and remove the two sealing washers (2). Discard the sealing washers.
Remove the tube assembly (3) from the cylinder block. Remove the O-ring seal (4) from the tube assembly. Discard the O-ring seal. Plug the port for the oil feed to the turbocharger with a suitable plug.
Remove the tube assembly (10) for the oil drain. Remove the two setscrews (11). Remove the two setscrews (8) and remove the tube assembly (10) from the turbocharger (6). Remove the joint (7) and remove the joint (9). Discard the joints.


Remove the four nuts (15) from the turbocharger (6) and remove the turbocharger (6) from the exhaust manifold (12). Ensure that the weight of the turbocharger is supported as the nuts are loosened.
Remove the joint (14). Discard the joint.
If necessary, remove the four studs (13) from the exhaust manifold (12).

Removal Procedure (Top Mounted Turbochargers)

Disconnect the air hose for the turbocharger inlet and for the turbocharger outlet.
If the turbocharger has a remote wastegate solenoid, disconnect the hose to the solenoid from the turbocharger. Disconnect the exhaust pipe.
If the turbocharger has an exhaust elbow, remove the exhaust elbow.


Remove the two setscrews (5) in order to disconnect the tube assembly (4) from the cylinder block. Remove the joint (3). Discard the joint.
Remove the setscrew (8) in order to disconnect the tube assembly (7) from the cylinder block. Remove the fasteners for the tube clips (2).
Loosen the four nuts (11). Refer to Illustration.
Remove the exhaust manifold (1) and the assembly of the turbocharger from the cylinder head.


Remove the banjo bolt (9) and remove the tube assembly (7) for the oil feed from the turbocharger (12). Remove the two sealing washers (10). Discard the sealing washers.
Remove the O-ring seal (6) from the tube assembly (7). Refer to Illustration. Discard the O-ring seal.
Remove the two setscrews (14) and remove the tube assembly (4) for the oil drain from the turbocharger (12). Remove the joint (13). Discard the joint.
Remove the four nuts (11) and remove the turbocharger (12) from the exhaust manifold (1). Remove the joint (15) from the exhaust manifold (1). Discard the joint. If necessary, remove the four studs (16) from the exhaust manifold (1).

Turbocharger – Disassemble Disassembly Procedure


Disconnect the pipe for the boost sensor (7) at the actuator (6).
Remove the circlip (1) that retains the actuator rod (4).
Remove the actuator rod (4) from the pin (2).
Remove the nuts (5) from the bracket (3).
Remove the actuator (6) from the bracket (3).
Do not attempt to disassemble the turbocharger cartridge assembly or wastegate. Do not remove the compressor wheel. The turbocharger cartridge assembly and the wastegate are not field serviced, and should be replaced only as a unit.

Turbocharger – Assemble Assembly Procedure

See illustration dissasambly procedure

Install the actuator (6) to the bracket (3). Install the nuts (5) to the bracket (3). Tighten the nuts to a torque of 5 N·m (44 lb in).
Connect the bottom of the actuator (6) to a suitable air supply with an accurate gauge. Operate the arm of the actuator by hand in order to check that the valve is free to move.
Push the arm of the wastegate valve toward the actuator (6) and hold the arm in position. Slowly apply air pressure to the actuator (6) until the pin (2) will fit into the actuator rod (4). Install the circlip (1) into the groove in the pin (2). Do not apply an air pressure of more than 205 kPa (29 psi) to the actuator. High pressures may damage the actuator.
Install the pipe for the boost pressure (7) to the actuator (6).