Perform this work only on a cold engine. Make sure all surfaces are cool
to the touch before beginning. Disconnect the negative battery cable.
Disconnect the exhaust pipe from the turbocharger and remove the gasket.
Remove the heat shield.
Remove the bolts holding the inlet fitting to the inlet manifold. Loosen
the hose clamps and remove the fitting; remove the rubber connecting hose.
Loosen the hose clamps from the oil return line and remove it.
Carefully disconnect the oil supply pipe from the top of the turbocharger.
Disconnect the vacuum hose from the top of the wastegate actuator. Remove
the wastegate actuator mounting bolts.
Remove the bolts holding the turbocharger to the exhaust flange. Remove
the turbocharger and discard the gasket.
Immediately after removing the turbocharger, plug the intake and exhaust
ports and the oil ports with clean, lint–free cloth rags or pieces of
crumpled paper. The turbocharger MUST be protected from dirt and grit; place
the unit in a protected location away from the work area.
Disconnect the intake manifold retaining bolts and remove the manifold.
Disconnect the exhaust manifold retaining bolts and remove the manifold.
Remove the gasket(s) and discard. Make certain the mating surfaces are completely
free of gasket material.
To install:
Install the new gasket and install the manifolds (exhaust first, then intake)
into position.
Start the retaining nuts and bolts by hand; tighten them to 12 ft. lbs.
(16 Nm) working from the center to the ends.
Remove the plugs from the turbocharger passages and install the turbocharger
with a new gasket onto the exhaust manifold. Tighten the nuts evenly.
Install the wastegate mounting bolts and tighten to 10 ft. lbs. (14 Nm).
Reconnect the wastegate actuator vacuum hose.
Connect the oil return line; make certain the clamp is secure.
Pour clean engine oil into the oil supply port to pre-lubricate the turbocharger.
Install the oil supply line and tighten it carefully.
Install the rubber connecting hose on the inlet fitting. Use a new gasket
and attach the inlet fitting to the intake manifold.
Use a new gasket and install the exhaust pipe to the bottom of the turbocharger.
Install the heat shield.
Start the engine, listening carefully for any sign of unusual noise from
either the manifolds or the turbocharger. Watch the oil pressure indicator
for any sign of incorrect pressure.
