Subaru Car 1998-05

Turbocharger

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Removal & Installation



1.8L Engine


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Fig. Turbocharger assembly-1.8L engine


WARNING
Do not allow dirt to enter either the inlet or outlet openings of the turbocharger, or the unit may be damaged at start-up.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Loosen the clamps and remove the air intake duct from the airflow meter (throttle body) and the turbocharger assembly.
  4.  
  5. Disconnect the vacuum lines from the waste gate valve controller.
  6.  
  7. Place a suitable drain pan beneath the turbo assembly. Loosen and remove the cooling and oil lines from the turbocharger.
  8.  
  9. Remove the mounting bolts from the turbocharger exhaust outlet. Separate the pipe from the turbocharger.
  10.  
  11. Remove the turbocharger.
  12.  
  13. Remove the sealing gaskets, and clean all gasket mating surfaces.
  14.  

To install:

  1. Using new gaskets, install the turbocharger on the exhaust manifold. Tighten the turbocharger mounting bolts to 18-25 ft. lbs. (25-34 Nm) alternately and evenly.
  2.  
  3. Install the oil and cooling lines. Tighten the oil line banjo bolt to 11-13 ft. lbs. (15-18 Nm) and the cooling line banjo bolt to 16-18 ft. lbs. (21-24 Nm).
  4.  
  5. Connect the vacuum line to the waste gate valve controller.
  6.  
  7. Install the air intake duct assembly.
    WARNING
    Do not run the engine at a high RPM during the first few minutes of operation after servicing. This may damage the turbocharger, as the pressurized oil may not reach the turbocharger immediately.

  8.  
  9. Start the engine and allow it to reach operating temperature. Check for leaks. Test drive the vehicle.
  10.  

2.0L Engine
  1. Remove or disconnect the following:

    Negative battery cable
     
    Center exhaust pipe
     
    Turbocharger joint pipe from the turbocharger
     
    Engine coolant hose from the filler tank
     
    Clamp that attaches the turbocharger to the inlet duct
     
    Bolt that attaches the bracket of the oil pipe to the turbocharger
     
    Oil pipe from the turbocharger
     
    Turbocharger bracket
     
    Oil outlet hose from the pipe
     
    Turbocharger.
     

  2.  

To install:

  1. Installation is the reverse of removal.
  2.  
  3. Tighten the front pipe to the turbocharger retainers to 22 ft. lbs. (30 Nm).
  4.  

2.5L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Remove the collector cover, if equipped.
  6.  
  7. On 2005 engines remove the intercooler and intercooler bracket.
  8.  
  9. Remove the center exhaust pipe.
  10.  
  11. Lower the vehicle.
  12.  
  13. Separate the turbocharger joint pipe from the turbocharger.
  14.  
  15. Disconnect the engine coolant hose from the coolant filler tank.
  16.  
  17. Loosen the clamp that attaches the turbocharger to the intake duct.
  18.  
  19. Remove the oil pipe-to-turbocharger bolt and remove the oil pipe from the turbocharger.
  20.  
  21. Remove the turbocharger bracket and disconnect the oil outlet hose from the pipe.
  22.  
  23. Remove the turbocharger.
  24.  

To install:

  1. Installation is the reverse of removal, please note the following torque specs:
    1. Turbocharger-to-intake duct: 2 ft. lbs. (3 Nm).
    2.  
    3. Oil pipe-to-turbocharger: 11 ft. lbs. (16 Nm).
    4.  
    5. Joint pipe-to-turbocharger using a new gasket: 25 ft. lbs. (35 Nm).
    6.  
    7. Turbocharger bracket: 24 ft. lbs. (33 Nm).
    8.  

  2.