- Before unscrewing parts, thoroughly clean the area 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;
- carefully close the lubrication holes if they cannot be immediately closed by the part being reinstalled;
- install only clean parts;
- remove spare parts from the 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 malfunctions, check the presence of oil in the air/air heat exchanger, for which remove it and wash it with a clean solvent;
- After driving over a long distance, check that the oil supply and return pipes from the turbocharger are not covered with even a slight layer of oil.
Removal
- Removal and installation of a turbocharger requires removal of the power unit.
- Remove the power unit
- Remove the turbocharger thermal shield.
- Remove the turbocharger support bracket and the 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.
- Lift the manifold slightly and remove the two screws securing the crankcase ventilation hose secured under the manifold.
- Remove the intake manifold and its gasket.
- Remove the four bolts securing the turbocharger to the exhaust manifold.
- Remove the turbocharger.
- Remove the pipe connected to the turbocharger outlet.
Installation
- Check the cleanliness of the turbocharger lubrication pipes.
- Installation is carried out in the reverse order of removal, with the obligatory replacement of clamps and self-locking nuts securing the turbocharger and the turbine outlet pipe.
- Replace all gaskets and observe the tightening torques of threaded connections.
Note. Make sure that the air/air heat exchanger is not filled with oil and that the engine oil return pipes from the turbocharger are not pinched or contaminated. Otherwise, remove the heat exchanger, clean it with a detergent and dry it well.
Attention. Before starting the engine, disconnect and insulate the engine stop solenoid valve connector located on the fuel pump, then operate the starter until the oil pressure warning light goes off
- 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.