Toyota Celica 1986-1993 Repair Guide

Turbocharger

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REMOVAL & INSTALLATION



The 3S-GTE engine uses a turbocharger. On 1988-89 models, the turbocharger is water-cooled. On 1990-93 models, the turbocharger is air-cooled.


WARNING
Make sure all wire, hoses and vacuum lines are marked to simplify installation. 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.


CAUTION
On models with an air bag, wait at least 30 seconds from the time that the ignition switch is turned to the lock position and the battery is disconnected before performing any further work.

1988-89 Vehicles
  1. Disconnect the negative battery cable. Raise and support the vehicle safely as necessary to complete this service operation.
  2.  
  3. Drain the engine coolant. Drain the intercooler coolant.
  4.  
  5. Remove the air cleaner assembly. Remove the catalytic converter and all necessary brackets.
  6.  
  7. Remove the oxygen sensor.
  8.  
  9. Remove the intercooler assembly, using the proper procedures.
  10.  
  11. Remove the alternator duct. Remove the No. 2 alternator mounting bracket.
  12.  
  13. Remove the turbocharger heat insulator.
  14.  
  15. Remove the heat insulator of turbine outlet elbow. Remove the turbine outlet elbow.
  16.  
  17. Remove the turbocharger retaining stay. Disconnect all water and oil pipe lines. Remove the turbocharger unit from the vehicle.
  18.  

To Install:


WARNING
After replacing the turbocharger assembly, pour or squirt new oil into the oil (about 20cc new oil) inlet and turn the impeller wheel by hand to splash (circulate) oil on the bearing.

  1. To install the turbocharger unit, install the turbocharger water pipe assembly, if equipped, and oil pipe assembly to the unit using new mounting gaskets.
  2.  
  3. Mount the turbocharger assembly, using new gaskets and temporarily tighten all nuts and bolts.
  4.  
  5. Torque the turbocharger to exhaust manifold mounting nuts to 47 ft. lbs. Connect all oil, water and vacuum hoses to the turbocharger assembly.
  6.  
  7. Install the turbocharger stay (mounting bracket) to the correct location.
  8.  
  9. Install the turbine outlet elbow.
  10.  
  11. Install heat insulator of turbine outlet elbow.
  12.  
  13. Install turbocharger heat insulator. Install the alternator bracket and alternator duct.
  14.  
  15. Install the intercooler assembly, using the proper procedures.
  16.  
  17. Install the oxygen sensor. Install the catalytic converter and all necessary brackets.
  18.  
  19. Install the air cleaner assembly.
  20.  
  21. Refill the engine and intercooler with the specified coolant to the correct level. Reconnect the battery cable and check oil level. Start engine check for any fluid leaks. Road test the vehicle for proper operation.
  22.  



Click image to see an enlarged view

Fig. Fig. 1 Turbocharger components1988-89 3S-GTE engine

1990-93 Vehicles
  1. Disconnect the negative battery cable. Raise and support the vehicle safely as necessary to complete this service operation.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Remove the air cleaner cap and engine undercovers.
  6.  
  7. Remove the suspension lower crossmember. Remove the front exhaust pipe.

    Click image to see an enlarged view

    Fig. Fig. 2 Turbocharger components1990-93 3S-GTE engine

  8.  
  9. Remove the engine mounting center member. Remove the front mounting insulator and bracket.
  10.  
  11. Remove the clutch release cylinder without disconnecting the tube. Remove the alternator.
  12.  
  13. Remove the idler pulley bracket and air conditioning compressor without disconnecting the hoses. Remove the catalytic converter.
  14.  
  15. Remove the intercooler cool air inlet and protector, then remove the intercooler.
  16.  
  17. Remove the oxygen sensor and remove the turbocharger heat insulators.
  18.  
  19. Disconnect all hoses from the turbocharger. Remove the turbocharger retaining stay. Disconnect all oil pipe lines and remove the turbocharger unit from the vehicle.
  20.  

To Install:


WARNING
After replacing the turbocharger assembly, pour or squirt new oil into the oil (about 20cc new oil) inlet and turn the impeller wheel by hand to splash (circulate) oil on the bearing.

  1. Installation is the reverse of removal. Use new gaskets. Torque the turbocharger-to-exhaust manifold nuts to 47 ft. lbs. (64 Nm). Torque the oil pipe-to-turbocharger nuts to 13 ft. lbs. (17 Nm). Torque the oil pipe-to-block bolt to 38 ft. lbs. (51 Nm). Torque the oxygen sensor nuts to 33 ft. lbs. (44 Nm).
  2.  
  3. Refill the engine with the specified coolant to the correct level. Reconnect the battery cable and check oil level. Start engine check for any fluid leaks. Road test the vehicle for proper operation.
  4.  

 
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