Contents: Removal 🠛 Installation 🠛
When working on a turbocharger, the following recommendations must be carefully observed:
- before unscrewing the parts, thoroughly clean the place where they are connected;
- place the removed parts on a clean, smooth surface and cover them with polyethylene or thick paper, but do not use a cloth with lint for this purpose;
- carefully seal grease holes if they cannot be immediately sealed by the part being reinstalled;
- install only clean parts;
- remove spare parts from packaging immediately before installing them;
- do not use parts that have been stored without packaging;
- after removing the turbocharger, do not work with compressed air or move the vehicle;
- if the turbocharger is faulty, check for oil in the air/air heat exchanger by removing it and washing it with clean solvent;
- after driving a long distance, check that the turbocharger oil supply and return pipes are not covered with even a thin layer of oil.
Removal
- Removal and installation of a turbocharger requires removal of the power unit.
- Remove the power unit
- Remove the turbocharger heat shield.
- Remove the turbocharger support bracket and front exhaust pipe.
- Remove the engine oil inlet and outlet pipes and the cooled support from the turbocharger.
- Remove the EGR capsule and its pipe.
- Remove the intake manifold mounting bolts.
- Raise the manifold slightly and remove the two screws securing the crankcase ventilation hose, which is secured under the manifold.
- Remove the intake manifold and its gasket.
- Remove the four turbocharger mounting bolts on the exhaust manifold.
- Remove the turbocharger.
- Remove the pipe connected to the turbocharger outlet.
Installation
- Check the turbocharger lubrication tubes for cleanliness.
- Installation is carried out in the reverse order of removal, with mandatory replacement of the clamps and self-locking nuts securing the turbocharger and the pipe at the turbine outlet.
- Replace all gaskets and observe tightening torques of threaded connections.
Note: Make sure that the air/air heat exchanger is not filled with oil and that the turbocharger engine oil return pipes are not pinched or dirty. If this is the case, remove the heat exchanger, clean it with a cleaning agent and dry it thoroughly.
Caution: Before starting the engine, disconnect and isolate the connector of the engine stop solenoid valve located on the fuel pump, then operate the starter until the oil pressure warning lamp goes out
- Connect the connector to the engine stop solenoid valve and start the engine
- Check for oil leaks at the oil pipe connections.
- Check and adjust boost pressure.