Mazda Car 2005-06

Turbocharger

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Removal & Installation



Mazdaspeed6
  1. Disconnect the negative battery cable.
  2.  
  3. Before servicing the vehicle, refer to the precautions section.
  4.  
  5. Remove the charge air cooler cover.
  6.  
  7. Remove the battery and tray.
  8.  
  9. Remove the air cleaner.
  10.  
  11. Remove the resonance chamber, remove the left hand front mudguard before removing the resonance chamber.
  12.  
  13. Disconnect the MAF/IAT sensor.
  14.  
  15. Remove the duct.
  16.  
  17. Remove the charge air cooler cover.
  18.  
  19. Remove the charge air cooler.
  20.  
  21. Remove the charge air cooler bracket.
  22.  
  23. Remove the air bypass valve.
  24.  
  25. Drain and recycle the engine coolant.
  26.  
  27. Remove the throttle body.
  28.  
  29. Disconnect the EGR valve connector.
  30.  
  31. Remove the air hose.
  32.  
  33. Remove the high pressure fuel pump bracket and the EGR pipe bracket.
  34.  
  35. Remove the fuel delivery pipe cover.
  36.  
  37. Remove the oil level gauge pipe.
  38.  
  39. Remove the drive belt.
  40.  
  41. Remove the power steering pump out of the way with the lines still attached.
  42.  
  43. Remove the vacuum hose.
  44.  
  45. Remove the intake manifold.
  46.  
  47. Remove the three way catalytic converter.
  48.  
  49. Disconnect the rear oxygen sensor connector.
  50.  
  51. Remove the front exhaust pipe.
    CAUTION
    When removing the cowl, a part or tool may hit the edge of the windshield and could damage it. Protect the windshield by covering it with a clean rag to prevent damage to the windshield.

  52.  
  53. Remove the cowl and the insulator under the cowl.
  54.  
  55. Remove the exhaust manifold upper side insulator.
  56.  
  57. Remove the alternator.
  58.  
  59. Remove the exhaust manifold lower side insulator.
  60.  
  61. Disconnect the front oxygen sensor connector.
  62.  
  63. Remove the warm up three-way catalytic converter top side insulator.
  64.  
  65. Remove the brake master back side vacuum hose.
  66.  
  67. Remove the oil pipes.
  68.  
  69. Remove the front oxygen sensor.
  70.  
  71. Remove the warm up three-way catalytic converter.
  72.  
  73. Remove the turbocharger.
  74.  

To install:

  1. Installation is the reverse of removal, note the following:
    1. Tighten the turbocharger bolts to 29-37 ft. lbs. (38-51 Nm).
    2.  
    3. Tighten the oil pipe installation bolt while the stopper of the oil pipe is faced to the turbocharger.
    4.  
    5. Tighten the wastegate Control Solenoid Valve bolts to 70-95 inch lbs. (8-11 Nm).
    6.  
    7. Tighten the intake manifold bolts to 13-16 ft. lbs. (17-23 Nm).
    8.  
    9. Tighten the fuel delivery pipe cover bolts to 13-16 ft. lbs. (17-23 Nm).
    10.  
    11. Tighten the charge air cooler bracket to 31-35 ft. lbs. (42-48 Nm).
    12.  
    13. Tighten the charge air cooler to 14-19 ft. lbs. (42-48 Nm).
      CAUTION
      When installing the charge air cooler cover, be careful not to damage the charge air cooler cover clips.

    14.  
    15. Tighten the throttle body installation bolts to 71-101 inch lbs. (8-11.5 Nm).
    16.  
    17. Perform the following when installing the air cleaner case:

      Verify that the rubber mounts are set in the air cleaner bracket
       
      Install the projections on the frame side.
       
      Verify that the projections on the frame side are installed securely.
       
      Install the projection on the engine side.
       
      Verify that the projection on the engine side installed securely.
       

    18.  

  2.  

 
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