Turbocharger, Removing and Installing

Turbocharger, removing and installing

Note: Replace gaskets and self-locking nuts.

Removing





^ Remove noise insulation panel (arrows).
^ Unbolt A/C compressor.

WARNING! Do NOT open A/C refrigerant circuit.





^ Unbolt turbocharger bracket -2,
^ Disconnect oil return line -l- at turbocharger and lay aside.
^ Remove air guide ducts -4- and -5- at turbocharger.
^ Remove pressure line banjo fitting -3-.
^ Disconnect hose from support for boost pressure regulation valve vacuum diaphragm.
^ Unbolt bracket for coolant supply line at boost pressure regulation valve vacuum diaphragm.
^ Use 3094 hose clamp to pinch off coolant supply hose.
^ Remove intake air duct between cowl and air cleaner housing.
^ Remove air cleaner housing cover.





^ Remove the following lines/harness connectors:
1 - At wastegate bypass regulator valve -N75-
2 - At Evaporative Emissions (EVAP) purge regulator valve -N80-
3 - At power output stage -N 122-
4 - At Mass Air Flow (MAF) sensor -G70-

Remove hose connections and remove air cleaner housing (arrows).
Remove engine covers.





^ Unbolt crankcase ventilation hose -1- at cylinder head cover and heat shield.
^ Unbolt both oil supply line bolts -3-.
^ Remove heat shield -4-.
^ Remove sleeve -2- from coolant return hose.
^ Use 3094 hose clamp to pinch off coolant return hose.
^ Remove coolant return hose at line to turbocharger. Line remains bolted to turbocharger.
^ Unbolt oil supply line -7- at turbocharger.

Note: The exhaust flexpipe must not be bent more than 10°, otherwise it maybe damaged.

^ Unbolt Three Way Catalytic Converter (TWC) from turbocharger -6-.
^ Unbolt turbocharger from exhaust manifold -5-.
^ Move turbocharger to side and remove coolant supply line banjo fitting.
^ Remove turbocharger.

Installing
Installation is the reverse of removal, noting the following:
^ Perform the following steps before tightening turbocharger:
- Loosely bolt coolant supply line to vacuum diaphragm for boost pressure regulation valve.
- Tighten banjo fitting, then tighten mounting bolt for bracket to proper torque.

Note: Add oil to turbocharger through oil supply line connection flange.

^ Fill up coolant.

WARNING! The cooling system is pressurized when the engine is warm. When opening the expansion tank, wear gloves and other appropriate protection, cover the cap with a cloth and open carefully to relieve system pressure slowly.

Note: After installing the turbocharger, let engine idle for approximately 1 minute without increasing engine speed. This ensures adequate oil supply to the turbocharger.

^ Check engine oil level.








Tightening torques