Turbocharger Assembly Installation Details for 1990-1993 Galant Models Equipped with 2.0L DOHC Engine (1 of 2)
1 - Radiator; 2 - Air supply hose connection branch pipe; 3 - Vacuum hose connection nipple; 4 - Air hose connection branch A; 5 - Oxygen sensor; 6 - Air outlet pipe; 7 - Sealing gasket; 8 - Heat shield A; 9 - Heat shield B; 10 - Self-locking nut; 11 - Power unit lifting eye; 12 - Hollow bolt of the nipple connection; 13 - Sealing gasket; 14 - Water hose connection branch; 15 - Water pipe connection branch pipe B; 16 - Self-locking nut; 17 - Sealing gasket; 18 - Exhaust manifold; 19 - Sealing gasket; 20 - Ring; 21 - Sealing gasket
Turbocharger Assembly Installation Details for 1990-1993 Galant Models Equipped with 2.0L DOHC Engine (2 of 2)
22 - Oil return pipe; 23 - Sealing gasket; 24 - Turbocharger; 25 - Hollow bolt of nipple connection; 26 - Sealing gasket; 27 - Water pipe B; 28 - Hollow bolt of nipple connection; 29 - Sealing gasket; 30 - Water tube A; 31 - Hollow bolt of nipple connection; 32 - Sealing gasket; 33 - Oil pipeline; 34 - Exhaust pipe; 35 - Sealing gasket
Engines 2.0L DOHC (only Galant 1990÷1993)
General information
Most turbocharger failures are related to oil supply problems. Leaks when the engine is turned off can lead to engine oil getting into the turbocharger and coking the oil flows - first of all, always check the patency of the oil supply and return lines. When connecting the oil path lines, be sure to replace both sealing washers of the hollow bolts of the union connections.
[The original article was published on: www.MitsubishiMan.ru]
Removal
1. Turbocharger installation details are shown in the illustrations.
2. Disconnect the negative cable from the battery.
If your car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery!
3. Drain the engine oil, drain the cooling system and remove the radiator. On models equipped with an air conditioning system, also remove the air conditioning fan assembly with the radiator.
To avoid burns, proceed with the above work only after the system has completely cooled down! Do not allow antifreeze to come into contact with exposed areas of the body or painted surfaces of the car. Wash off any accidental splashes immediately with plenty of water. Remember that antifreeze is a highly toxic liquid and its ingestion, even in small quantities, can have the most serious consequences (even fatal). Never leave antifreeze stored in a loosely closed container and immediately collect any coolant spilled on the floor. Remember that the sweet smell of antifreeze can attract the attention of children and animals. Consult any car service station for information on how to dispose of used coolant. In many regions of the world, special collection points for various types of waste have been set up. Never pour old coolant down the drain or onto the ground!
4. Disconnect the electrical wiring and remove the oxygen sensor.
5. Remove the engine oil dipstick and its guide tube.
6. Remove the corrugated air intake hose, vacuum relief hose, air outlet hose connections, and the upper and lower heat shields.
7. Unbolt the steering pump and move it to the side together with the support bracket, without disconnecting the hydraulic hoses.
8. Loosen the self-locking nuts securing the exhaust manifold, remove the triangular lifting eye of the power unit, unscrew the hollow bolt of the union nut of the oil supply line to the central section of the turbocharger (do not forget to remove both sealing washers), and also disconnect the lines of the cooling tract.
The water line running under the turbocharger assembly is equipped with a threaded nipple connection.
9. Loosen the mounting nuts, disconnect the exhaust pipe and separate the exhaust manifold and its sealing gasket from the engine.
10. Remove the two through bolts and two nuts securing the exhaust manifold to the turbocharger assembly.
11. Remove the two screws from the return oil line that runs under the turbocharger assembly, remove the sealing gasket. Separate the turbocharger from the exhaust manifold (two water path tubes and one oil line can be left connected).
12. Carefully inspect the turbine wheels (hot section of the assembly) and compressor wheels (cold section) for cracks and other mechanical damage. Manually check the freedom of rotation of both wheels. Make sure there are no signs of developing oil leaks. Check the ability of the drain valve to remain open. Replace defective components, clean the oil flows if necessary.
13. The condition of the relief device can be checked by pressure testing. Apply approximately 62 kPa of pressure to the actuator and check that the rod can be moved.
Applying pressure greater than 71 kPa may damage the diaphragm! When creating a vacuum on the actuator, the latter must be reliably maintained - if leaks are detected, replace the assembly.
Do not attempt to adjust the release valve!
Installation
1. Fill the oil return line with clean engine oil. Replace all lock nuts. Before installing the threaded connection of the water inlet pipe, lightly lubricate the inside surface of the connecting flange with liquid oil. Install the turbocharger on the exhaust manifold.
2. Install the exhaust manifold assembly in its original place (do not forget to replace the sealing gasket).
3. Connect the cooling system lines, oil supply line and lifting eye of the power unit.
4. If removed, reinstall the steering pump assembly with its support bracket.
5. Install heat shields, air outlet pipe, drain hose and corrugated air ducts.
6. Install the radiator assembly.
7. Fill the engine with fresh motor oil, fill the cooling system and connect the negative cable to the battery.