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Turbocharger

On-vehicle inspection of turbocharger

  1. Inspect intake air system.

    Check for leakage or clogging between the air cleaner and turbocharger inlet and between the turbocharger outlet and cylinder head.

    • Clogged air cleaner ... Clean or replace element
    • Hoses collapsed or deformed ... Repair or replace
    • Leakage from connections ... Check each connection and repair
    • Cracks in components ... Check and replace

  2. Inspect exhaust system.

    Check for leakage or clogging between the cylinder head and turbocharger inlet and between the turbocharger outlet and exhaust pipe.

    • Deformed components ... Repair or replace
    • Foreign material in passages ... Remove
    • Leakage from components ... Repair or replace
    • Cracks in components ... Check and replace

  3. Inspect actuator operation.

    1. Disconnect the actuator hose.
    2. Using SST (turbocharger pressure gauge), apply approx. 0.66 kg/cm² (9.4 psi, 65 kPa) of pressure to the actuator and check that the rod moves.

    If the rod does not move, replace the turbocharger assembly.

    SST 09992-00241

    Notice

    Never apply more than 0.83 kg/cm² (11.8 psi, 81 kPa) of pressure to the actuator.

  4. Check turbocharging pressure.

    1. Using a 3-way connector, connect SST (turbocharger pressure gauge) to the hose between the intake manifold and turbocharging pressure sensor.

      SST 09992-00241

    2. While driving with the engine running at 2,800 rpm or more with the throttle valve fully open in the 3rd gear, check the turbocharging pressure.

      Standard pressure: 0.50 – 0.83 kg/cm² (7.1 – 11.8 psi, 49 – 81 kPa)

    If the pressure is less than that specified, check the intake air and exhaust systems for leakage. If there is no leakage, replace the turbocharger assembly.

    If the pressure is above specification, check if the actuator hose is disconnected or cracked. If not, replace the turbocharger assembly.

  5. Inspect impeller wheel rotation. (See Inspection of turbocharger, step 1)

  6. Inspect turbocharging pressure VSV. (See page FI-165)
  7. Inspect turbocharging pressure sensor. (See page FI-171)

Components

Removal of turbocharger

  1. Disconnect cable from negative terminal of battery.

    Caution

    Work must be started after approx. 20 seconds or longer from the time the ignition switch is turned to the LOCK position and the negative (–) terminal cable is disconnected from the battery.

  2. Drain engine coolant. (See page CO-6)

  3. Remove engine under covers.
  4. Remove LH engine hood side panel.
  5. Remove suspension upper brace. (See Cylinder block (3S-GTE) › Removal of engine, step 8)
  6. Remove air cleaner. (See Cylinder block (3S-GTE) › Removal of engine, step 9)
  7. Remove No.1 and No.2 air intake connectors. (See Intercooler, steps 4, 5)
  8. Disconnect transaxle control cables. (See Cylinder block (3S-GTE) › Removal of engine, step 29)
  9. Remove front exhaust pipe. (See Cylinder block (3S-GTE) › Removal of engine, steps 30, 31)
  10. Remove idler pulley bracket and A/C compressor. (See Intercooler › Removal of intercooler, steps 10–12)
  11. Remove front engine mounting insulator. (See Cylinder block (3S-GTE) › Removal of engine, step 38)
  12. Remove front mounting bracket and clutch release cylinder. (See Cylinder block (3S-GTE) › Removal of engine, step 39)
  13. Remove engine compartment cooling fan. (See steps 4 and 5 on page CO-34)
  14. Remove catalytic converter. (See Cylinder head (3S-GTE) › Removal of cylinder head, step 14)

  15. Disconnect air by-pass hoses.

    1. Disconnect the hose and VTV from the clamp.
    2. Disconnect the two air by-pass hoses.

  16. Remove clamps of air by-pass hose and VTV.

    Remove the bolt and two clamps.

  17. Remove air by-pass valve.

    1. Remove the bolt and air by-pass valve.
    2. Remove the O-ring from the air by-pass valve.

  18. Remove No.4 air tube.

    1. Remove the four bolts and air tube stay.

    2. Loosen the hose clamp, and remove the air tube.

  19. Remove turbocharger heat insulator.

    Remove the three bolts and heat insulator.

  20. Remove oxygen sensor.

    1. Disconnect the oxygen sensor connector.
    2. Remove the two nuts, oxygen sensor and gasket.

  21. Remove heat insulators of turbine outlet elbow.

    1. Remove the oil dipstick.
    2. Remove the three bolts and RH heat insulator.
    3. Remove the two bolts and LH heat insulator.

  22. Disconnect hoses.

    1. Water hose from water inlet housing
    2. Water by-pass hose from water by-pass pipe
    3. Vacuum hose from actuator

    4. Oil hose from turbo oil pipe

  23. Remove turbocharger stay.

    Remove the three bolts and turbocharger stay.

  24. Remove turbocharger.

    1. Remove the bolt and union bolt holding the No.1 turbo oil pipe to the cylinder block. Remove the two union bolt gaskets.

    2. Remove the four nuts, turbocharger and gasket.

  25. Remove turbo oil pipe.

    Remove the two nuts, oil pipe and gasket.

  26. Remove turbo water pipe.

    Remove the two nuts, two bolts, water pipe and gasket.

  27. Remove side bearing housing plate.

    Remove the two nuts, housing plate and gasket.

  28. Remove turbine outlet elbow.

    Remove the six nuts, outlet elbow and gasket.

Inspection of turbocharger

  1. Inspect impeller wheel rotation.

    Grasp the edge of the turbine wheel and turn it. Check that the impeller wheel turns smoothly.

    If the impeller wheel does not turn or if it turns with a drag, replace the turbocharger assembly.

  2. Inspect axial play of impeller wheel.

    Insert a dial indicator into the intake side hole the turbine wheel edge by and check the axial play.

    Standard clearance: 0.13 mm (0.0051 in.) or less

    If the axial play is not as specified, replace the turbocharger assembly.

  3. Inspect radial play of impeller wheel.

    1. From oil outlet hole, insert a dial indicator through the hole in the spacer bearing and set it in the center of the impeller shaft.
    2. Move the impeller shaft in a radial direction, measure the radial play of the impeller shaft.

    Standard clearance: 0.18 mm (0.0071 in.) or less

    If the radial play is not as specified, replace the turbocharger assembly.

  4. Inspect air by-pass valve.

    1. Apply vacuum to port A, and check that the valve is open.

    2. In the preceding condition, apply vacuum to port B, and check that the valve is closed.

    If operation is not as specified, replace the air by-pass valve.

  5. Inspect VTV (for air by-pass valve).

    1. Check that air flows without resistance from ports B to A.
    2. Check that air flows without difficulty from ports A to B.

    If operation is not as specified, replace the VTV.

Installation of turbocharger

(See On-vehicle inspection of turbocharger)

Notice

After replacing the turbocharger assembly, pour approx. 20 cc (1.2 cu in.) of new oil into the oil inlet and turn the impeller wheel by hand to splash oil on the bearing.

  1. Install turbine outlet elbow.

    Install a new gasket and the outlet elbow with the six nuts.

    Torque: 650 kg-cm (47 ft-lb, 64 N·m)

  2. Install side bearing housing plate.

    Install a new gasket and the housing plate with the two nuts.

    Torque: 120 kg-cm (9 ft-lb, 11 N·m)

  3. Install turbo water pipe.

    Install a new gasket and the water pipe with the two nuts and two bolts.

    Torque: 120 kg-cm (9 ft-lb, 11 N·m)

  4. Install turbo oil pipe.

    1. Align the oil holes of a new gasket and the turbocharger housing.
    2. Install the gasket and oil pipe with the two nuts. Do not torque the nuts yet.

  5. Install turbocharger.

    1. Install a new gasket and the turbocharger with the four nuts. Do not torque the nuts.

    2. Install the oil pipe with the bolt, two new gaskets and union bolt. Do not torque the bolt and union bolt.

    3. Tighten the four nuts holding the turbocharger to the exhaust manifold.

      Torque: 650 kg-cm (47 ft-lb, 64 N·m)

    4. Tighten the two nuts holding the oil pipe to the turbocharger.

      Torque: 175 kg-cm (13 ft-lb, 17 N·m)

    5. Tighten the union bolt holding the oil pipe to the cylinder block.

      Torque: 525 kg-cm (38 ft-lb, 51 N·m)

    6. Tighten the union bolt holding the oil pipe to the cylinder block.

      Torque: 440 kg-cm (32 ft-lb, 43 N·m)

  6. Install turbocharger stay.

    Install the turbocharger stay with the three bolts.

    Torque:

    • To turbocharger – 705 kg-cm (51 ft-lb, 69 N·m)
    • To cylinder block – 600 kg-cm (43 ft-lb, 59 N·m)

  7. Connect hoses.

    1. Water hose from water inlet housing
    2. Water by-pass hose from water by-pass pipe
    3. Vacuum hose from actuator

    4. Oil hose from turbo oil pipe

  8. Install heat insulators of turbine outlet elbow.

    1. Install the RH heat insulator with the three bolts.
    2. Install the LH heat insulator with the two bolts.
    3. Install the oil dipstick gauge.

  9. Install oxygen sensor.

    1. Install a new gasket and the oxygen sensor with the two nuts.

      Torque: 450 kg-cm (33 ft-lb, 44 N·m)

    2. Connect the oxygen sensor connector.

  10. Install turbocharger heat insulator.

    Install the heat insulator with the three bolts.

  11. Install No.4 air tube.

    1. Connect the air connector and air tube to the turbocharger.

    2. Install the air tube stay with the four bolts.

      Torque: 195 kg-cm (14 ft-lb, 19 N·m)

  12. Install air by-pass valve.

    1. Install a new O-ring to the air by-pass valve.

    2. Apply soapy water on the O-ring.

    3. Install the air by-pass valve with the bolt.

      Torque: 195 kg-cm (14 ft-lb, 19 N·m)

  13. Install clamps of air by-pass hose and VTV.

    Install the two clamps with the bolt.

  14. Connect air by-pass hoses.

    1. Connect the two air by-pass hoses.
    2. Install the air by-pass hose and VTV to the clamps.

  15. Install catalytic converter. (See Cylinder head (3S-GTE) › Installation of cylinder head, step 28)

  16. Install engine compartment cooling fan. (See steps 1 and 2 on page CO-36)
  17. Install front mounting bracket and clutch release cylinder. (See Cylinder block (3S-GTE) › Installation of engine, step 9)
  18. Install front engine mounting insulator. (See Cylinder block (3S-GTE) › Installation of engine, step 10)
  19. Install A/C compressor and idler pulley bracket. (See Intercooler › Installation of intercooler, steps 3–5)
  20. Install front exhaust pipe. (See Cylinder block (3S-GTE) › Installation of engine, steps 18, 19)
  21. Connect transaxle control cables. (See Cylinder block (3S-GTE) › Installation of engine, step 20)
  22. Install No.1 and No.2 air intake connectors. (See Intercooler › Installation of intercooler, steps 10, 11)
  23. Install air cleaner. (See Cylinder block (3S-GTE) › Installation of engine, step 40)
  24. Install suspension upper brace. (See Cylinder block (3S-GTE) › Installation of engine, step 41)

  25. Fill engine with coolant. (See page CO-7)

    Capacity (w/ heater): 13.6 liters (14.4 US qts, 12.0 Imp. qts)

  26. Connect cable to negative terminal of battery.

  27. Start engine and check for leaks.
  28. Check engine oil level.
  29. Install LH engine hood side panel.
  30. Install engine under covers.