Removal and installation a turbocharger
Removal the turbocharger
1. Place the vehicle on a two-post lift.
2. Disconnect the negative battery terminal.
3. Remove the front engine cover.
4. Loosen the mounting bolts and remove the engine protective pan.
5. Remove the catalytic converter (see the relevant section below).
6. Remove the turbocharger return oil line (see chapter "Lubrication system").
7. Remove the turbocharger air outlet duct (see "Intercooler Inlet Duct").
8. Remove the turbocharger pressure oil line (see chapter "Lubrication system").
9. Disconnect the boost pressure control valve control hose from the turbocharger.
10. Unscrew the nuts (1) and remove the turbocharger with gaskets.
Installing a turbocharger
Attention:
- It is necessary to make sure that no foreign objects got into the turbine or compressor during installation. Make sure that the turbocharger return oil line is not clogged with scale. Check for leaks, if any are found, replace the part with a new one.
- Depending on the turbocharger malfunction, it is necessary to check the intermediate cooler and air circuit for the absence of oil in them. 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 turbocharger, the turbocharger mounting nuts and the exhaust manifold threaded studs with new ones (if they were weakened).
1. Using fine-grained sandpaper, clean the contact surfaces of the exhaust manifold and turbocharger (if reused).
2. Use a cleaning agent to clean and degrease the surfaces of the exhaust manifold and turbocharger (if reused).
3. If replacing the turbocharger threaded studs, tighten them to a torque of 9 Nm.
4. Install a new gasket between the exhaust manifold and the turbocharger onto the exhaust manifold.
5. Install the turbocharger.
6. Using an open-end wrench, tighten the turbocharger nuts without tightening them (the turbocharger should rest against the manifold, and the key should not turn without resistance).
7. Use a marker to mark the lower nut and the surface of the turbocharger.
8. Tighten the lower turbocharger nut until the mark on the nut rotates relative to the turbocharger by 60°.
9. Using a torque wrench, tighten the remaining two turbocharger nuts to 28 Nm.
10. Add some clean engine oil into the turbocharger oil circuit to facilitate restoration of oil circulation.
11. Connect the boost pressure control valve control hose.
12. Install the turbocharger pressure oil line (see chapter "Lubrication system").
13. Install the turbocharger air outlet duct.
14. Install the turbocharger return oil line (see chapter "Lubrication system").
15. Install the catalytic converter.
16. Install the engine protective pan.
17. Install the engine cover.
18. Connect the negative battery terminal.