Air Induction Systems: Turbocharger: Removal

1. Disconnect the negative battery cable.
2. Drain the engine coolant.
3. Disconnect the vacuum hose leading to the air bypass valve and the turbocharger wastegate actuator. See Fig 1.
4. Unfasten the purge solenoid valve from the charge air cooler outlet duct pipe near the throttle body.
5. Remove the charge air cooler inlet duct pipe between the turbocharger compressor outlet and the charge air cooler top end-tank. See Fig 1.
6. Remove the air inlet duct pipe between the MAF and the turbocharger compressor inlet.
7. Remove the charge air cooler outlet duct pipe between the charge air cooler bottom end-tank and the throttle body. See Fig 1.
8. Cap or tape off all openings of the turbo compressor, charge air cooler and the throttle body. This will prevent foreign objects or debris from entering during repair.
9. Disconnect harness connections from both cooling fans.
10. Remove the radiator with intercooler and both fans attached.
11. Disconnect and remove front Heated Oxygen Sensor (HO2S). See Fig 1.
12. Remove exhaust manifold insulator. See Fig 1.
13. Remove insulator of the front pipe (between the turbo down pipe and the catalytic converter).
14. Remove the front pipe.
15. Remove intake manifold brace from rear of engine.
16. Disconnect turbocharger oil feed line fitting from three-way tee adapter at the rear of engine. See Fig 1.
17. Remove turbo down pipe support bracket.
18. Disconnect turbocharger oil drain block from oil pan upper block. See Fig 1.
19. Loosen EGR pipe nut fully.
20. Disconnect turbocharger coolant feed hose from pipe branch.
21. Disconnect turbocharger coolant return pipe from three-way hose. See Fig 1.
22. Remove bolts and nuts securing exhaust manifold to cylinder head.
CAUTION: DO NOT lift the assembly by the turbocharger wastegate actuation rod or any of the coolant pipe branches. Lift mainly by the exhaust manifold and turbocharger housing castings.
23. Remove primary turbocharger assembly (includes: turbocharger, turbo down pipe, oil and coolant connections attached). See Fig 1.

Fig 1: Identifying Turbo Charger Components

Courtesy of MAZDA MOTORS CORP.