Turbocharger
REMOVAL & INSTALLATION
2.2L Engine
See Figure 1
Before starting the following procedure, clean the area around the turbocharger assembly with a non-caustic solution. After the turbocharger is removed, cover the openings to prevent the entry of foreign material while it is off the engine.
During removal, be careful not to bend, nick, or in any way damage the compressor wheel blades. Damage may result in rotating assembly imbalance, and bearing and oil seal failure. Any time a turbocharger assembly has been removed, gently spin the turbine wheel before reassembly to ensure the rotating assembly does not bind.
Any time an engine bearing (main bearing, connecting rod bearing, camshaft bearing) has been damaged in a turbocharged engine, the oil and filter should be changed and the turbocharger flushed with clean engine oil to reduce the possibility of contamination.
- Disconnect the negative battery cable.
- Raise and safely support the vehicle. Remove the engine undercover and drain the cooling system.
- Remove the inlet and outlet hoses from the turbocharger. Cover the turbocharger openings with clean rags to prevent the entry of dirt or foreign material.
- Remove the retaining bolts and remove the insulator covers from the exhaust manifold and turbocharger.
- Disconnect the coolant hoses.
- Disconnect the oil feed and return lines. Cover the openings in the turbocharger to prevent the entry of dirt or foreign material.
- Disconnect the oxygen sensor connector. Disconnect the EGR pipe from the exhaust manifold.
- Remove the nuts and disconnect the exhaust pipe from the turbocharger. Remove the bolt from the turbocharger support bracket.
- Remove the exhaust manifold-to-cylinder head nuts while supporting the manifold/turbocharger assembly.
- Remove the exhaust manifold and turbocharger as an assembly.
- Remove the nuts and separate the manifold from the turbocharger.
Do not carry the turbocharger by the actuator rod. Be careful not to bend the actuator mounting or rod.
- Clean all gasket mating surfaces of sealant and old gasket material.
- Assemble the exhaust manifold to the turbocharger, using a new gasket. Tighten the nuts to 34 ft. lbs. (46 Nm).
- Pour approximately 0.85 oz. (25 ml) of clean engine oil into the turbocharger oil inlet.
- Install the turbocharger/exhaust manifold assembly to the cylinder head, using a new gasket. Tighten the nuts to 34 ft. lbs. (46 Nm).
- Connect the support bracket to the turbocharger. Tighten the bolt to 30 ft. lbs. (41 Nm).
- Connect the exhaust pipe to the turbocharger, using a new gasket. Tighten the nuts to 34 ft. lbs. (46 Nm).
- Connect the EGR pipe to the exhaust manifold. Connect the oxygen sensor connector.
- Connect the oil feed and return lines. Connect the coolant hoses.
- Install the insulators on the exhaust manifold and turbocharger and secure with the bolts.
- Install the turbocharger inlet and outlet hoses.
- Check the engine oil level and add, as necessary. Change the oil and filter if the oil is dirty.
- Install the engine undercover and lower the vehicle.
- On 323, disconnect the connector from the ignition coil negative terminal. Disconnect the connector from the igniter.
- Connect the negative battery cable and crank the engine for at least 20 seconds.
- Reconnect the electrical connector. Fill and bleed the cooling system.
- Start the engine and run at idle for 30 seconds.
- Stop the engine and disconnect the negative battery cable. Depress the brake pedal for at least 5 seconds to cancel the malfunction code.
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For more car related problem troubleshooting:---
This are the sections, you can go through and click the link to read its troubleshooting.
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The car will not start?
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Car will not crank?
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Car has no spark?
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How to troubleshoot car battery?
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How to test starter solenoid?
http://schematicsdiagram.blogspot.com/2011/06/how-to-test-starter-solenoid.html
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How to test cars starter?
http://schematicsdiagram.blogspot.com/2011/06/how-to-test-cars-starter.html
How to replace starter in car?
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car will turn over but will not start?
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The Brake Indicator Light Stays On dash of car?
The ABS and Traction Control Lights stays ON dash of car?
Check Engine Light On car?
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How to replace Interior Lights on car?
Car lights not working, even after replacing the bulb/lamp?
Click this link below:--
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How to replace head lights on car?
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How to replace Parking, turn, and Brake Lights on car?
http://schematicsdiagram.blogspot.com/2011/06/how-to-replace-parking-turn-and-brake.html
How to remove the door panel on car?
How to remove the door panel on car?
How to replace power window motor in car?
How to test relays on car?
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How to troubleshoot Engine Misfires?
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The spark plug firing order for car?
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Where is the Thermostat located in car?
How to recharge AC on Auto/Truck/car?
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How to trouble shoot speedometer?
To Order car parts online:--To get heavy discount on car parts .Click this link below:----
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How to Replace a Fuel Injector
How to Replace a C.O.P. Type Ignition Coil?
How to Replace a Fuel Pressure Regulator?
How to Replace a Fuel Pump?
How to Replace a Rear Lift Gate Locking Mechanism?
How to Clean a Fuel System
How to Replace an Ignition Coil
How to Replace a Windshield
How to Replace a Mass Air Flow Sensor
How to Replace a Rear Distance Sensor
How to Replace a Muffler
How to Replace an Engine
How to Replace an Intake Manifold Gasket
How to Replace an Oil Pump
How to Lubricate a Brake Pedal Linkage ?
How to Replace a Windshield Wiper Motor
How to Replace a Distributor Cap
How to Replace a Door Weather Stripping
How to Replace a Freeze Plug
How to Replace a Head Gasket
How to Replace a Heater Core
How to Replace Spark Plugs?
How to Replace a Rear Axle Bearing?
How to Replace a Front Bumper Cover
How to Replace a Manual Transmission
How to Replace a Headlight Bulb
How to Replace a Headlight Switch
How to Replace Windshield Wiper Blades
How to Replace a Cooling Fan
How to Replace a Catalytic Converter
How to Replace an Engine Mount
How to Replace a Fog Light Assembly
How to Change Engine Oil and Filter
How to Replace a Power Seat Switch
How to Replace a Rear Main Seal
How to Repair a Defroster Grid
How to Replace an AWD Transfer Case
How to Replace a Plastic License Plate Bracket?
How to Replace a Power Seat Motor
How to Replace Power Steering Fluid
How to Replace a Power Window Switch
How to Replace a Quarter Glass Panel?
How to Pressure Test a Radiator and Cap
How to Replace a Radiator
How to Repair a Hood.
How to Replace an Energy Absorber
How to Replace Heater Core Hoses
How to Replace a Thermostat.
How to Rotate Tires.
How to Replace Wheel Lug Nuts
How to Replace a Tire Valve Stem
How to Change a Flat Tire
How to Replace Leaf Springs
How to Replace a Heater Control Valve
How to Replace Transmission Cooler Lines
How to Replace an Ignition Control Unit
How to Replace a Brake Hose
How to Replace a Transfer Case Rear Output Seal
How to Replace a Seat Belt and Seatbelt Retractor
How to Replace a Power Steering Rack
How to Bleed Brakes with a Tool
How to Replace a Tail Light Bulb
How to Check Automatic Transmission Fluid Level
How to Change Automatic Transmission Fluid and Filter
How to Replace Vacuum Hoses
How to Replace an Air Intake Boot
How to Replace a Valve Cover Gasket
How to Replace a Water Pump
How to Replace a Windshield Wiper Switch
How to Replace Window Run Channel Seals
How to Replace a Window Regulator
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How to Replace a Window Motor
How to Adjust a Hood Release Latch?
How to Replace a Radiator Support
How to Replace a Rear Pinion Seal.
How to Replace Battery Cables
How to Replace a Proportioning Valve
How to Replace an Upper Radiator Hose
How to Replace a Lower Radiator Hose
How to Replace a Timing Belt?
How to Check for Loose or Worn Suspension
How to Check for Loose Steering System
How to Replace an Oil Pressure Switch (Sensor)
How to Replace a Fender Liner or Splash Shield
How to Replace a Hood Insulator
How to Replace a Rear Differential.
How to Repair a Hood Hinge
How to Replace a Brake Pedal Return Spring
How to Replace a Door Shell.
How to Replace a Transfer Case Front Output Seal
How to Replace a Hood Latch/Lock Assembly
How to Replace a Lift Gate Strut
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How to Check Differential Oil Leaks and Replace Oil.
How to Replace a Mirror
How to Replace a Transfer Case Shift Linkage
How to Replace a Transmission Mount
How to Replace a U-Joint
How to Replace a Washer Tank
How to Replace an A/C Line or Hose
How to Replace a Heater and A/C Blower Motor
How to Replace an ABS Control Unit
How to Perform a Brake Adjustment
How to Replace an Alternator Belt
How to Replace an Emblem
How to Replace an Exhaust Manifold Gasket
How to Replace a Tail Pipe
How to Replace Shock Absorbers
How to Replace a Strut Assembly
How to Replace a Driveshaft
How to Replace a Wheel Cylinder
How to Replace a Hood
How to Replace a Brake Disc (Rotor)
How to Replace a Metal License Plate Bracket
How to Replace a Power Steering Pump
How to Perform a Basic Engine Tune-Up
How to Perform a Basic Engine Tune Up-Oil Change
How to Perform a Basic Engine Tune Up-Spark Plug and Wire Change
How to Replace a Distributor Cap and Rotor ?
How to Repair a Valance
How to Replace a Turn Signal Switch
How to Replace a Plastic Bumper Cover
How to Replace a Parking Brake Cable
How to Replace Windshield Wiper Blade Refills
How to Replace a Corner Light
How to Replace a Bumper Bracket or Side Support
How to Replace a Washer Pump.
How to Replace a Grille
How to Replace a Locking Hub
How to Replace a Fender
How to Replace a Power Steering Hose
How to Replace a Tailgate
How to Replace a Soft Top
How to Replace a Carburetor
How to Replace a Bumper Trim
How to Replace Trunk Strut
How to Replace a Front End Cover
How to Replace a Front Pipe
How to Replace an Antenna Mast
How to Replace a Side Marker Light Assembly
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How to Replace a Spoiler
How to Replace a Mirror Glass on car?
How to Replace a Step Bumper?
How to Replace a Door Lock
How to Replace a Throttle Body
How to Replace a Throttle Position Sensor
How to Replace a Grille Insert
How to Replace a Fan Shroud Assembly
How to Replace an Engine Splash Shield
How to Replace a Turn Signal Light Assembly
How to Replace a Headlight Assembly
How to Replace a Park Light Assembly
How to Replace an Expansion Tank
How to Replace an Exhaust System
How to Replace a Fender Trim
How to Replace a Headlight Door
How to Replace a Fan Shroud
How to Replace a Harmonic Balancer
How to Replace a Header Panel
How to Replace a Fuel Tank
How to Replace a Fuel Tank Cap
How to Replace a Distributor
How to Replace an EGR Valve
How to Replace an Oxygen Sensor
How to Replace an Ignition Wire Set
How to Replace a Tail Light
How to Replace a Door Handle
How to Replace a Hood Strut
How to Replace Tail Light Assembly
How to Replace a Front Bumper
How to Replace a Fuel Pump Assembly
How to Replace an Axle Assembly
How to Replace a Tailgate Handle
How to Replace a Wheel Hub Assembly
How to Replace a Control Arm
How to Replace a Window Regulator with Motor
How to Replace a Headlight
How to Check the Brake Fluid Level
How to Replace a Parking Brake Switch
How to Replace a Blower Motor Resistor
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Horn stopped working?
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Cruise control stopped working?
Car is stuck in park and the shift will not move?
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