GM Metro/Sprint 1985-1993 Repair Guide

Turbocharger

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REMOVAL and INSTALLATION

See Figure 1



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Fig. Fig. 1: Turbocharger assembly

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. As required, remove the hood and front grille to gain access to components.
  2.  
  3. Remove the intercooler.
  4.  
  5. Remove the radiator hoses and fan motor electrical connector.
  6.  
  7. Remove the front upper member.
  8.  
  9. Remove the radiator and air conditioning condenser.
  10.  
  11. Remove the front bumper.
  12.  
  13. Remove the exhaust pipe bolts.
  14.  
  15. Remove the air conditioning compressor and lay it aside.
  16.  
  17. Remove the turbocharger top and side covers.
  18.  
  19. Disconnect the oxygen sensor electrical connector.
  20.  
  21. Remove the upper and lower exhaust pipes as a unit after removing the bracket bolt.
  22.  
  23. Remove the air inlet and outlet pipes from the turbocharger.
  24.  
  25. Remove the turbocharger oil pipes from the cylinder block.
  26.  
  27. Remove the turbocharger water pipes.
  28.  
  29. Unbolt and remove the turbocharger.
  30.  

To install:
  1. Turn the turbocharger by hand and check the blades for damage. Check the inside of the housing for oil deposits. If found, replace the turbocharger assembly.
  2.  
  3. Check the oil pipe orifices for clogs. If found clear the obstruction.
  4.  
  5. Install the air inlet pipe to the turbocharger using a new gasket. Tighten bolts to 6-8 ft. lbs.. (8-12 Nm).
  6.  
  7. Install the oil pipe to the turbocharger and air inlet pipe using a new gasket.
  8.  
  9. Install the turbocharger on the exhaust manifold using a new gasket. Tighten bolts to 13-20 ft. lbs.. (18-28 Nm).
  10.  
  11. Install the water hoses to the turbocharger and cylinder head.
  12.  
  13. Install the oil drain hose. Tighten to 3-5 ft. lbs.. (4-7 Nm).
  14.  
  15. Install the oil inlet pipe on the cylinder head using a new gasket. Tighten to 8-10 ft. lbs.. (11-15 Nm).
  16.  
  17. Install the air inlet tube clamp bolt to the cylinder head.
  18.  
  19. Install the air outlet pipe using a new gasket. Tighten bolt to 6-8 ft. lbs.. (8-12 Nm).
  20.  
  21. Install the upper and lower exhaust pipes. Tighten bolts to 18-25 ft. lbs.. (25-35 Nm) and nuts to 13-20 ft. lbs.. (18-28 Nm).
  22.  
  23. Install the lower exhaust pipe bracket bolt and tighten to 29-43 ft. lbs.. (40-60 Nm).
  24.  
  25. Install the turbocharger covers.
  26.  
  27. Connect the oxygen sensor electrical connector.
  28.  
  29. Install the air conditioning compressor and belt.
  30.  
  31. Install the front bumper, radiator and air conditioning condenser.
  32.  
  33. Connect the radiator fan motor electrical connector.
  34.  
  35. Install the radiator hoses, intercooler, front grille and hood.
  36.  
  37. Fill the engine with coolant and connect the negative battery cable.
  38.  
  39. Start the engine and allow it to reach normal operating temperature. Check for leaks.
  40.  

 
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