Removal and installation of a turbocharger
Removing the turbocharger
1. Place the vehicle on a two post lift.
2. Disconnect the negative battery terminal.
3. Remove the engine front cover.
4. Unscrew the fastening bolts and remove the engine protective tray.
5. Remove catalytic converter (see related section below).
6. Remove turbocharger oil return line (see chapter "Lubrication system").
7. Remove the turbocharger outlet duct (see "Intercooler intake duct").
8. Remove the pressure oil pipe of the turbocharger (see chapter "Lubrication system").
9. Disconnect the boost pressure control valve control hose from the turbocharger.
10. Loosen the nuts (1) and remove the turbocharger with gaskets.
Turbocharger Installation
Attention:
- It must be ensured that no foreign objects have entered the turbine or compressor during the installation process. Check that the turbocharger oil return line is not clogged with scale. Check for leaks, if found, replace the part with a new one.
- Depending on the faulty turbocharger, the intercooler and air circuit must be checked for oil. If oil is found in the air circuit, it is necessary to remove the corresponding component and clean it using a special station, and then dry it with compressed air.
Note: Be sure to replace the gaskets between the exhaust manifold and the turbocharger, the turbocharger mounting nuts and the exhaust manifold threaded studs with new ones (if they were weakened).
1. Using fine sandpaper, clean the contact surfaces of the exhaust manifold and turbocharger (if reused).
2. Clean and degrease the surfaces of the exhaust manifold and turbocharger with a cleaning agent (if reused).
3. If replacing the turbocharger threaded studs, screw them in with a torque of 9 Nm.
4. Install a new gasket between the exhaust manifold and turbocharger on the exhaust manifold.
5. Install the turbocharger.
6. Use an open-end wrench to start, without tightening, the nuts of the turbocharger (the turbocharger must rest against the manifold, and the key must not turn without resistance).
7. Use a marker to mark the bottom nut and the surface of the turbocharger.
8. Tighten the lower turbocharger nut so that the marked mark on the nut rotates 60°relative to the turbocharger.
9. Using a torque wrench, tighten the remaining two turbocharger nuts to 28 Nm.
10. Put some clean engine oil into the turbocharger oil circuit to help restore oil circulation.
11. Connect the control hose for the boost pressure control valve.
12. Install the turbocharger pressure oil pipe (see chapter "Lubrication system").
13. Install the turbocharger outlet duct.
14. Install turbocharger oil return line (see chapter "Lubrication system").
15. Install catalytic converter.
16. Install the engine protection tray.
17. Install the engine cover.
18. Connect the negative battery terminal.