Turbocharger

Complete removal and replacement of the turbocharger assembly on the 1.5L turbocharged engine, including disconnection of oil feed/return lines, coolant lines, and exhaust components.

Warnings

Tools required

Parts

• Turbocharger assembly × 1 — Use OEM specification
• Turbo oil feed line crush washers × 2 — Use OEM specification
• Turbo oil return line gasket × 1 — Use OEM specification
• Exhaust manifold gasket × 1 — Use OEM specification
• Turbo-to-downpipe gasket × 1 — Use OEM specification
• Coolant line gaskets/O-rings × 1 — Use OEM specification
• Engine oil (for topping off) × 1 — Honda Genuine 0W-20
• Honda Type 2 Coolant × 1 — Pre-diluted blue coolant

Fluids

• Honda Genuine 0W-20 — 0.5 qt
• Honda Type 2 Coolant (Blue) — 1.5 qt

Preparation

1. Ensure engine is completely cool (minimum 2 hours after last operation)
2. Disconnect negative battery terminal and wait 3 minutes for airbag system discharge
3. Raise vehicle and secure on jack stands, ensuring stable support
4. Remove engine splash shield and undercovers
5. Drain engine coolant by opening radiator drain valve and collecting fluid in appropriate container
6. Remove engine cover by pulling upward on clip fasteners
7. Apply penetrating oil to all exhaust fasteners and allow to soak for 15-20 minutes

Procedure

1. 1

   Remove heat shields and air intake components
   Remove the turbocharger heat shield by removing the mounting bolts. Disconnect the air intake tube from the turbocharger inlet. Remove the intercooler inlet pipe from the turbo compressor outlet. Label all connections for reassembly.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
2. 2

   Disconnect turbo coolant lines
   Locate the coolant feed and return lines at the top of the turbocharger. Place a drain pan underneath to catch residual coolant. Loosen the coolant line fittings and disconnect both lines from the turbocharger. Plug open coolant ports immediately to prevent debris contamination.
   ⚠Even with drained system, hot coolant may remain in turbocharger passages. Wear gloves and eye protection.
   Torque spec

   Coolant Line Fittings15 Nm (11 lb-ft)
3. 3

   Remove turbocharger oil feed line
   Working from above, locate the oil feed line banjo bolt at the top of the turbocharger center housing. Position drain pan to catch oil spillage. Remove the banjo bolt and disconnect the oil feed line. Note the orientation of crush washers. Allow residual oil to drain completely. Cap or plug the opening to prevent debris entry.
   ⚠Oil feed line is under residual pressure. Expect oil spillage when disconnecting. Have absorbent materials ready.
   Torque spec

   Oil Feed Line20 Nm (15 lb-ft)
4. 4

   Disconnect oxygen sensors and electrical connectors
   Disconnect the primary oxygen sensor electrical connector located before the turbocharger. Using an oxygen sensor socket, carefully remove the sensor from the exhaust manifold (save for reinstallation if in good condition). Disconnect any electrical connectors attached to the turbocharger assembly, including wastegate actuator if equipped with electrical connection.
   Torque spec

   Sensor Bolts10 Nm (8 lb-ft)
5. 5

   Remove turbocharger-to-downpipe connection
   Working from underneath the vehicle, locate the connection between turbocharger outlet and downpipe. Apply additional penetrating oil if needed. Remove the three bolts securing the downpipe to the turbo. Separate the joint and remove the old gasket. Support the downpipe to prevent stress on remaining exhaust hangers.
   ⚠Exhaust studs are prone to breaking on these models. Work slowly and use penetrating oil generously. If stud breaks, extraction will be required before reassembly.
   Torque spec

   Turbo-to-Downpipe Bolts45 Nm (33 lb-ft)
6. 6

   Remove oil return line
   From underneath the vehicle, locate the oil return line connection at the bottom of the turbocharger center housing where it connects to the oil pan. Remove the bolts securing the return line flange. Carefully lower and remove the oil return line. Remove and discard the old gasket.
   Torque spec

   Oil Return Line10 Nm (7 lb-ft)
7. 7

   Unbolt turbocharger from exhaust manifold
   Working from the engine bay, locate the bolts/nuts securing the turbocharger to the exhaust manifold (typically 4 fasteners). Apply anti-seize was already applied during previous service - remove fasteners working from the coolest (furthest from engine) to hottest location. Keep fasteners organized as they may be different lengths.
   Torque spec

   Turbo-to-Manifold Bolts35 Nm (26 lb-ft)
8. 8

   Remove turbocharger assembly
   With all connections disconnected, carefully maneuver the turbocharger assembly out of the engine bay. The turbo must be lifted upward and rotated to clear surrounding components. Take care not to damage coolant lines, wiring, or other nearby components. Once removed, cover all open ports on engine and turbocharger mounting location.
   ℹ️Turbocharger weighs approximately 15-20 lbs and is awkwardly shaped. Use care when lifting out of tight engine bay.
9. 9

   Clean and inspect mounting surfaces
   Thoroughly clean the exhaust manifold mating surface using a wire brush and gasket scraper. Remove all old gasket material and carbon deposits. Inspect manifold surface for warping, cracks, or damage. Clean the oil feed port, oil return port, and coolant port threads on the engine block. Inspect all mounting studs for damage or thread wear.
   ⚠Do not allow debris to fall into open oil return port or feed line. Cover openings while cleaning.
10. 10

    Prepare and install new turbocharger
    Remove protective covers from new/replacement turbocharger. Apply clean engine oil to the turbo bearing housing through the oil inlet port - rotate the shaft by hand while adding oil to distribute internally. Install new exhaust manifold gasket onto the manifold studs. Apply anti-seize compound to turbo-to-manifold bolt threads. Carefully position the turbocharger onto the exhaust manifold, ensuring gasket remains properly seated.
    ⚠Pre-lubricating the turbocharger bearing is critical. Failure to do so will cause immediate damage upon first startup.
11. 11

    Secure turbocharger to manifold
    Install and hand-tighten all turbo-to-manifold bolts. Using a torque wrench, tighten bolts in a cross-pattern to specified torque. Verify the turbocharger is properly seated against the manifold with no gaps visible around the gasket perimeter.
    Torque spec

    Turbo-to-Manifold Bolts35 Nm (26 lb-ft)
12. 12

    Install oil return line
    Position new oil return line gasket on the turbo center housing. Align the oil return line to both the turbocharger and oil pan connection points. Install mounting bolts and tighten to specification. Verify the line has no kinks or stress points.
    Torque spec

    Oil Return Line10 Nm (7 lb-ft)
13. 13

    Connect turbo to downpipe
    Install new turbo-to-downpipe gasket. Align downpipe to turbo outlet flange. Apply anti-seize to bolt threads. Install bolts and tighten in a cross-pattern to specification. Verify proper gasket seating and no exhaust leaks visible.
    Torque spec

    Turbo-to-Downpipe Bolts45 Nm (33 lb-ft)
14. 14

    Install oil feed line with new crush washers
    Install NEW crush washers on both sides of the oil feed line banjo fitting (discard old washers). Position oil feed line to turbocharger center housing oil inlet. Install banjo bolt with washers and tighten to specification. Do not over-torque as this will damage crush washers and cause leaks.
    ⚠Always use NEW crush washers. Reusing old washers will result in oil leaks and potential turbo failure from oil starvation.
    Torque spec

    Oil Feed Line20 Nm (15 lb-ft)
15. 15

    Reconnect coolant lines and remaining components
    Install new O-rings or gaskets on coolant line fittings. Connect coolant feed and return lines to turbocharger and tighten to specification. Reinstall oxygen sensor with anti-seize on threads (torque per sensor specifications). Reconnect all electrical connectors including O2 sensor and wastegate actuator. Reinstall heat shields and tighten bolts to specification. Reconnect intercooler piping and air intake tube.
    Torque spec

    Coolant Line Fittings15 Nm (11 lb-ft)

    Heat Shield Bolts10 Nm (7 lb-ft)

    Sensor Bolts10 Nm (8 lb-ft)

Reassembly

1. Reinstall engine undercovers and splash shields
2. Refill cooling system with Honda Type 2 coolant to proper level using funnel at radiator and reservoir
3. Check engine oil level and top off if necessary with Honda Genuine 0W-20 oil
4. Reconnect negative battery terminal
5. Before starting engine, disable fuel system (remove fuel pump fuse) and crank engine for 10-15 seconds to pre-lubricate turbocharger bearings
6. Reinstall fuel pump fuse and start engine

Verification

• With engine running, carefully inspect all connection points for oil, coolant, and exhaust leaks while engine is at idle
• Check for unusual noises from turbocharger area (grinding, squealing, or rattling indicates installation problem)
• Allow engine to reach operating temperature and verify coolant level remains stable with no leaks
• Bleed cooling system by running engine with radiator cap off until thermostat opens and air bubbles cease
• Test drive vehicle and verify normal boost pressure and performance. Listen for exhaust leaks under acceleration
• After test drive, re-inspect all connections while engine is hot for any signs of leakage
• Check engine oil level after test drive and top off if needed
• Monitor oil consumption and coolant level over the next 100 miles to ensure no slow leaks have developed

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