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Fuel System: Turbocharger: Removal

  1. Drain radiator and remove negative battery cable. Remove throttle body air intake tube. Disconnect intercooler hose from turbocharger assembly. Disconnect O2 sensor. Remove lower heat shield retaining bolts and lower heat shield from turbocharger. Remove upper heat shield retaining bolts and upper heat shield from exhaust manifold.
  2. Slide O2 sensor wire and guide through upper heat shield. Remove side heat shield retaining bolts from turbocharger, and remove side heat shield. Remove power steering belt. Remove power steering pump through bolt and adjuster nuts and bolts. Disconnect lower radiator hose from water pump.
  3. Pull pump from bracket, and position pump to access mounting bracket retaining nut and bolts. Remove mounting bracket-to-engine nut and bolts and remove bracket. Remove air cleaner duct retaining screws. Loosen clamp at turbocharger and move duct tube out of way. Disconnect coolant supply hose at turbocharger.
  4. Remove bolt and sealing washers attaching oil supply line at engine block. Raise vehicle on hoist. Remove nuts and washers from exhaust pipe flange. Remove bolts attaching exhaust hanger to engine block. Slide rubber exhaust hangers from catalytic converter. Pull exhaust pipe downward and to left side of vehicle. Disconnect oil return hose from turbocharger. Disconnect coolant return hose from turbocharger.
  5. Remove turbocharger support bracket retaining bolts. Remove coolant by-pass tube outlet-to-water pump bolts. Lower vehicle. Loosen retaining clamp bolt on coolant by-pass tube at rear of cylinder head. Remove 11 retaining nuts from exhaust manifold. Position coolant by-pass tube out of way after pulling bracket from exhaust stud.
  6. Remove exhaust manifold by pulling off studs and moving assembly towards right side of engine compartment, clearing cooling fan. With assembly removed from vehicle, remove turbocharger-to-exhaust manifold nuts. Separate assembly and discard gasket.
CAUTION: Before installing turbocharger, put .8 oz. (25 ml) engine oil into turbocharger oil inlet.
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