Removal - Installation
Article: Dan Birch Photos:Dan Birch
As these vehicles are second hand
and have an unknonw history it is hard to tell just what sort of condition it
is in internally.
My vehicle when purchased was in what i saw great condition (mechanicaly) in stock form. Unfortunalty i got the modification
bug and started strapping on accesorise. after this i decided the surf needed some more power to help push it all along. So
along i went to Brisbane Tuning and Turbo centre who gave me a power up which included a 2.5" exhaust, free flow muffler
and increased my turbo boost to 11psi from stock 7psi. A Big increase indeed. but in doing this showed their was a hidden
problem with my turbocharger unit which was not visible at lower psi. It would have eventually become visible, but due to
the extra stress it was put under it did so more quickly.
CT20 - Usuall Repair Bill - $500 - $1000 depending on problem.
The task : Now toyota wouldn't make this easy for us would they...
Tools: 10mm, 12mm, 14mm spanners.
+ some skin on the knuckles !!
Time Taken: 3-5 Hours
Difficulty: 3.5 (Fairly fiddly)
Step 1: Preparing the Engine Bay
Firstly remove the air ducting form the
air cleaner to the turbo inlet. This will give you a lot more
Step 2: Removing the Manifolds
Make sure to cover up the inlet manifold
so as dirt does not get in there, or you don't loose anything
Then remove the tubing from the turbo to the inlet manifold
Step 3: Removing the Outer Parts
Next step was to remove the heat shielding aroung the
turbo unit, there were 4 bolts alltogehter and this
Step 4:Watch for spills.
The cooling inlet/outler in the turbo will have some coolent inside it - soak this up with some tissue as this is corrosive if dripped on anything. When i removed a part i made sure to replace the bolts back onto the unit where that part was so not to get them mixed up.
Step 5: Removing Exhaust Manifold
Next remove the exhuast manifold at the rear of the turbo. This is done using a 12mm spanner and there are 4 bolts alltogheter. It is recomended that you loosen or removethe 14mm bolts holding the turbo unit to the exhaust manifold on the engine side bfore hand - so as to nor cause damage or stress to any part of the unit.
Step 6: Removing the Turbo
Once the exhaust side is off the only tricky
bit is to remove the oil lines into and out of the turbo. This is located
directly underneath the turbocahrge and is a real pain to do. The left
hand side bolt is easy to remove as you have space, the iner bolt is just
above the heatshield for the ehxuast. So it is very tight in there and
a knuckle breaker !!
Once these are loosened and the bolts reomved the whole unit can be removed easily in one upward pull.
Step 7: Checking Tubing
Here you can see the turbo removed. Make sure nothing
falls into the outlet of the exhaust (engine side) and into the oil tubing
which is hanging in the middle of the image. This is a good chance to
check everything is all ok around this area and if you want
The engine bay certanitly looks bear without the turbo unit !!
The newer turbo unit needed some parts transferring
off the old unit which was done easily. The installtion is very easy
compared to uninstalling the unit. Make sure you use some exhaust cement on both sides of the turbo charger when re-
assembling. Tighten all bolts very well ! Make sure -as much as a pain it is- that the oil lines into and out of the turbo are
extremely tight as you don't want to loose oi pressure here.
Once it is all back in place check the radiator coolent level and if needs be top up as required.
then take it for a drive - you may notice some abnormal smoke which could be due to the exhuast cement or oil in the system
this is just it burning off. The newer unit had a much healthier sound to it and much more responsive. Check for leaks when you
return - keep in eye on oil level over the next week or so to check the turbo charger is in good working order.