Note. When installing, use new nuts securing the turbocharger to the exhaust manifold. If a new turbocharger is installed, new exhaust manifold-to-turbocharger nuts and new cooling line seals will be required.
Turbocharger Mounts and Hose/Tube Connections
Reset bolts and nuts for fastening the turbocharger to the manifold are marked:
A - Bottom bracket; B - Oil outlet pipe coupling; C - Lower turbocharger cooling hose; E - Upper turbocharger cooling hose; F - Oil feed pipe coupling
Removing
1. While the engine is warm, treat the turbocharger mounting bolts with special oil to make them easier to remove.
2. Apply the handbrake, then jack up the front of the vehicle and place it on axle stands.
3. Make sure that the engine has cooled down sufficiently, then, on F8Q engines, drain the liquid from the cooling system as described in Chapter Maintenance.
4. Where applicable, remove the top motor skid plate.
5. Remove the front of the exhaust system and the muffler/converter downpipe, refer to Section General description and replacement of exhaust system components.
6. Working under the vehicle, remove the top mounting nut and bolt and the bottom bolt, and remove the turbocharger bottom bracket (refer to illustrations).
7. Unscrew the oil drain pipe coupling from the back of the turbocharger (refer to accompanying illustration). Be prepared for oil to come out.
8. On models with an F8Q engine, cut the clamp and disconnect the lower cooling hose from the turbocharger pipe (refer to accompanying illustration). Be prepared for coolant to come out.
9. Working in the engine compartment, unscrew the reinforcing rod between the domes of the front suspension struts.
10. Remove the air filter assembly as described in Section Removal and installation of a casing of the air filter.
11. Loosen the clamps and remove the air duct connecting the intake manifold to the intercooler.
12. Loosen the clamps and remove the air duct connecting the air filter to the turbocharger. Also disconnect the breather hose connecting the air duct to the intake manifold. Note the location of the brackets on the duct.
13. Loosen the clamp and disconnect the air outlet (going to the intercooler) from the turbocharger.
14. Remove the nut securing the preheat control unit to the bulkhead and move the unit aside without disconnecting the wiring.
15. Turn away a nut and disconnect a vacuum tube from the vacuum pump (refer to accompanying illustration).
16. On models with an F8Q engine, disconnect the coolant hose from the rear of the cylinder head and move the hose to the side (refer to accompanying illustration).
17. In the same way, disconnect the upper hose of the turbocharger cooling system (refer to accompanying illustration).
18. Unscrew the nut and disconnect the oil feed pipe from the top of the turbocharger (refer to accompanying illustration). It may be necessary to remove the bypass system bracket to gain access to the union nut.
19. Remove a bolt and a nut of an arm of fastening of an elbow duct to a turbocharger and get an arm (refer to accompanying illustration).
20. Disconnect the boost pressure pipe from the intake manifold (refer to accompanying illustration).
21. Unscrew the four nuts securing the turbocharger to the manifold, and remove the turbocharger from the studs on the manifold (refer to accompanying illustration). To improve access to the nuts, unscrew the exhaust manifold from the turbocharger.
22. Get the turbocharger up, passing it under the vacuum pump, and then leading it out between the vacuum pump and the expansion tank (refer to accompanying illustration).
23. If a new turbocharger is being installed, remove the coolant pipes and exhaust manifold from the old block and replace them with the new one. Use new nuts when installing the exhaust manifold, and new seals when installing the coolant pipe.
Installation
1. Install in reverse order, but replace any damaged clamps, and use new turbocharger-to-exhaust manifold nuts, which should be tightened as shown in Specifications effort. Tighten the connecting nuts of the oil supply and return pipes to the turbocharger as shown in Specifications effort. Where applicable, the exhaust manifold must be fitted to the turbocharger using new nuts. Fill the cooling system as described in Chapter Maintenance.
2. Finally, before starting the engine, you must perform the following steps.
- a) Disconnect the wiring from the fuel cutoff valve on the fuel pump and isolate the connector.
- b) Crank the engine over with the starter until the pressure warning light on the instrument panel goes out (this may take a few seconds).
- With) Connect the wiring harness to the fuel cutoff valve, then start the engine.
- d) Let the engine idle and check the turbocharger for oil and coolant leaks. Fix all problems.
3. After starting the engine, check the engine oil level and top up if necessary.