TGlO TURBOCHARGER SYSTEM - Turbocharger

I I REMOVAL OF TURBOCHARGER
(See page TC-9)
1. DRAIN ENGINE COOLANT (See page CO-4)

2. REMOVE INTAKE PlPE

(a) Disconnect the vacuum hoses for the boost compen-
sator.
(b) Disconnect the air hose clamp bolt.
(c) Remove the three nuts, intake pipe and gasket.

3. DISCONNECT WATER BY-PASS HOSES

4. REMOVE TURBO HEAT INSULATORS

Remove the four bolts and three heat insulators.

5. REMOVE EXHAUST MANIFOLD STAY

Remove the two bolts, two nuts and exhaust manifold
stay.

6. REMOVE TURBO O I L PlPE

(a) Remove the union bolt and two gaskets holding the
turbo oil pipe to the cylinder block.
(b) Disconnect the turbo oil hose.
(c) Remove the two nuts, turbo oil pipe and gasket.

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 TURBOCHARGER SYSTEM - Turbocharger TC-11

7. REMOVE TURBOCHARGER FROM EXHAUST 4

M A Nl FOLD
Remove the four nuts, turbocharger and gasket.

8. REMOVE TURBO WATER PIPE

Remove the bolt and two nuts, turbo water pipe and
gasket.

9. REMOVETURBINEOUTLETELBOW
Remove the four nuts, turbine outlet elbow and gasket.

INSPECTION OF TURBOCHARGER
1. INSPECT IMPELLER WHEEL ROTATION
Grasp the edge of the turbine wheel and turn it. Check
that the impeller wheel turns smoothly.
I f the impeller wheel does not turn or if it turns with a
drag, replace the turbocharger assem bly.

2. INSPECT A X I A L PLAY O F IMPELLER WHEEL

Insert a dial indicator into the intake side, hold the turbine
wheel edge by hand and check the axial play.
Axial play: 0.13 mm (0.0051 in.) or less
I f the axial play is not as specified, replace the turbocharger
assembly.

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 TC-12 TURBOCHARGER SYSTEM - Turbocharger

INSPECT RADIAL PLAY OF TURBINE SHAFT

(a) From the oil outlet hole, insert the dial indicator
through the hole in the spacer bearing and set it in
the center of the turbine shaft.
(b) Moving the turbine shaft in a radial direction, meas-
ure the radial play of the shaft.
Radial play: 0.18 mm (0.0071 in.) or less
I f the radial play is not as specified, replace the turbo-
charger assembly.

4. INSPECT ACT1JATOR OPERATION

(a) Disconnect the actuator hose.
(b) Using SST (turbocharger pressure gauge), apply ap-
prox. 0.81 kg/cm2 (11.5 psi, 79 kPa) of pressure to
the actuator and check that the rod moves.
SST 09992-00241
I f the rod does not move, replace the turbocharger assem-
bly.
NOTICE: Never apply more than 0.95 kg/cm2 (13.5 psi,
94 kPa) of pressure to the actuator.

NOTICE: After replacing the turbocharger assembly,

pour approx. 20 cc (1.2 cu in.) of new oil into the oil inlet
and turn the impeller wheel by hand to splash oil on the
bearing.

INSTALL TURBINE OUTLET ELBOW

l nstall a new gasket and the turbine outlet elbow with the
four nuts.
Torque: 260 kg-cm (19 ft-lb, 25 N-m)

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 TURBOCHARGER SYSTEM - Turbocharaer TC- 13

2. INSTALL TURBO WATER PIPE +

lnstall a new gasket and the water pipe with the two nuts
and bolt.
Torque: 80 kgcm (69 in.-lb, 7.8 N-m)

3. INSTALL TURBOCHARGER TO EXHAUST

MAN I FOLD
(a) lnstall a new gasket to the exhaust manifold.

(b) lnstall the turbocharger with the four nuts.

Torque: 530 kg-cm (38 ft-lb, 52 Nom)

4. INSTALL TURBO OIL PlPE

(a) lnstall a new gasket and the turbo oil pipe with the
two nuts.
Torque: 195 kg-cm (14 ft-lb, 19 N-m)
(b) Connect the turbo oil hose.
(c) lnstall two new gaskets and the union bolt of the
turbo oil pipe.
Torque: 260 kgcm (19 ft-lb, 25 N-m)

5. INSTALL EXHAUST MANIFOLD STAY

lnstall the exhaust manifold stay with the two bolts and
two nuts.
Torque: 195 kg-cm ( 14 ft-lb, 19 N-m)

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 TC-14 TURBOCHARGER SYSTEM - Turbocharger
6. INSTALL TURBOCHARGER HEAT INSULATOR
Install the three heat insulators with the four bolts.
Torque: 120 kg-cm (9 ft-lb, 12 N-m)

7. CONNECT WATER BY-PASS HOSES

8. INSTALL INTAKE PIPE

(a) Connect the air hose and install a new gasket and the
intake pipe with the three nuts.
Torque: 120 kg-cm (9 ft-lb, 12 Nsm)
(b) Connect boost compensator vacuum hoses.

9. Fl LL ENGINE WITH COOLANT (See page CO-5)

10. START ENGINE AND CHECK FOR LEAKS

11. CHECK ENGINE O I L LEVEL

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 FU- 1

FUEL SYSTEM
REFER TO 2L. 3L ENGINE REPAIR MANUAL
(Pub. No. RM123E)

NOTE: The following pages contain only the points which

differ from the above listed manual.

Page
FUEL HEATER SYSTEM (LJ) ................................... FU-2
INJECTION PUMP ................................................. FU-3

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