Remove:
- collar (2) from the inlet hose of the solenoid valve for controlling the pneumatic drive of the boost pressure regulator;
- collar (3) from the boost pressure control valve hose.
Disconnect:
- inlet hose of the solenoid valve of the boost pressure regulator;
- boost pressure control valve hose.
Remove the air outlet duct from the air filter housing (see description above).
Remove the turbocharger heat shield (see description above). Disconnect the turbocharger cooling system hoses (see description above).
Remove turbocharger oil lines (see description above).
Open the clamp (10) turbocharger vacuum hose and disconnect it.
Remove:
- bracket mounting nut (11) compressor;
- turbocharger bracket bolts (12) from the cylinder head cover;
- turbocharger bracket.
Remove nuts (13) lower mounting of the turbocharger.
Remove:
- top nuts (14) turbocharger mounts;
- turbocharger;
- gasket between turbocharger and exhaust manifold.
Replace gasket between exhaust manifold and turbocharger, exhaust manifold-to-turbocharger mounting studs (in case of turning), turbocharger fastening nuts.
Use swabs to clean the mating surface:
- exhaust manifold,
- turbocharger, if it is reused.
Use a cleaner to clean and degrease the mating surfaces:
- exhaust manifold;
- turbocharger, if reused.
Note. If the turbocharger stud came loose during the removal operation, replace it with a new one and lubricate with a high strength locking compound.
Torque tighten the new turbocharger studs to 9 Nm.
Attention. Make sure that no foreign objects get into the turbine or compressor during installation.
Check that the turbocharger oil outlet line is not partially or completely blocked by carbon deposits.
Make sure there is no fuel leakage.
Check for leaks, if there are, replace the part.
When replacing a turbocharger
Remove:
- bolts of fastening of the pipeline of cooling of a turbocompressor;
- bolts of fastening of the pipeline of the cooling system of the turbocharger;
- pipeline of the turbocharger cooling system.
Torque tighten the turbocharger cooling system pipe bolts 40 Nm.
When installing, tighten to the required torque:
- new nuts on the turbocharger (preload) 10 Nm;
- new nuts on the turbocharger 20 Nm.
Install all parts in reverse order.