9-3 1999

Turbocharger

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Hose from the charge air cooler
     
    Front exhaust pipe from the engine. Take care not to damage the Oxygen (O 2 S) Sensor electrical wiring harness.
     
    Locking ring on the wastegate after breaking the seal
     
    Oil return pipe from the turbocharger
     
    Oil pipe from the oil filter housing
     
    Hose to the boost control valve
     
    Nuts from the wastegate diaphragm
     
    Intake pipe and wastegate as a unit
     
    Intake pipe and the bypass hose
     
    Turbocharger coolant pipe with the oil pipe
     
    Turbocharger and discard the gasket
     

  6.  

To install:

  1. Install or connect the following:
    WARNING
    It is very important that there is oil in the turbocharger when the engine is started to avoid damage to the unit.



    Turbocharger with a new gasket and torque the nuts to 16 ft. lbs. (22 Nm) and fill the turbocharger interchamber passage with engine oil.
     



    Turbocharger coolant and oil pipes
     
    Intake pipe for the turbocharger
     
    Wastegate with the boost pressure control valve and pipes
     
    Intake hose with the bypass hose
     
    Locking ring and seal for the wastegate
     
    Front pipe to the turbocharger
     
    Hose connecting the charge air cooler with the turbocharger
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system and check the oil level.
  4.  
  5. Reseal the boost pressure control rod.
  6.  
  7. Test drive the vehicle for proper operation.
  8.  

 
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