Basic information
1. The turbocharger is installed under the exhaust manifold. Lubrication is provided by a special oil supply pipe that is screwed into the cylinder head. The oil returns to the sump through a return pipe that connects to the side of the cylinder. The turbocharger has an integral turbine bypass valve and a vacuum diaphragm which is used to limit the pressure of the air entering the intake manifold.
2. Turbocharger parts rotate at a very high speed and are therefore very sensitive to contamination. Small particles of dust can cause significant damage to the compressor, especially if they get on the turbine blades. Please read the precautions and warnings below before working on the turbine.
Warning. Thoroughly clean the area around all tubing connections before disconnecting them. This will protect the tubes from dirt getting inside. To prevent contamination, store removed parts in a closed container. Cover the turbocharger air ducts to prevent debris from getting inside and clean only with a lint-free cloth.
Precautionary measures. Do not start the engine with the compressor air connection disconnected: the intake vacuum builds up very quickly if the engine speed increases and there is a risk of foreign particles being sucked in and then thrown out at a very high speed.
Removing
3. Disconnect the negative battery terminal.
4. Where provided, remove the engine bottom shield as described in Chapter 11.
5. Where necessary, refer to the relevant part of this Chapter, and remove the air cleaner. On vehicles equipped with an oxidation trap, unscrew the screw and remove the heat shield located between the air cleaner and the oxidation trap.
6. Loosen the latches and disconnect the pipe from the air cleaner to the turbocharger (see fig. 6.6).
Pic. 6.6. Turbocharger assembly
A From the air cleaner
B To intake manifold
C From exhaust manifold
D To exhaust pipe
E Turbocharger
F Oil pipe
G Oxidation trap
H Charging air tube
I Support post
J EGR valve
K Bracket
7. Disconnect the vacuum hoses from the compressor bypass valve diaphragm housing and, where provided, the EGR valve. Note the location of the hoses and the color coding to make it easier to reinstall.
8. Where provided, loosen the fasteners, then disconnect and remove the bellows from the EGR valve base.
9. Where provided, unscrew the nuts and remove the oxidation trap from the exhaust manifold along with the bracket. Note: On vehicles without a trap, an intermediate pipe is installed in its place.
10. Loosen the clamps and disconnect the pipe from the turbocharger to the intake manifold.
11. Loosen the clamps and disconnect the mixing tube (where it is installed) based on the EGR valve from the turbocharger.
12. Loosen the fittings and disconnect the oil supply and return pipes from the turbocharger - be prepared for oil to spill. Remove the sealing washers and dispose of them - new ones will be required during installation. Release the oil supply pipe from the clamp on the intake manifold.
13. Turn away nuts and disconnect a reception pipe of system of release of the fulfilled gases from a turbocharger exit. Remove the gasket - a new one is required during installation.
14. Loosen and turn away bolts of fastening of the compressor to an arm and a rack, remove the compressor from under a final collector.
Installation
15. Installation of the turbocharger is carried out in the reverse order, taking into account the following points:
- A) Before tightening the bolts securing the compressor to the bracket, tighten the exhaust pipe nuts by hand.
- b) Apply high temperature grease to the threads and heads of the new intermediate tube/oxidation trap bolts. Then install and tighten them to the specified torque.
- V) Tighten downpipe nuts securely.
- G) Before connecting the fittings and finally tightening them, fill the oil supply pipe and the turbocharger inlet pipe with clean engine oil.
- d) Tighten the oil return pipe fitting securely.
- e) Connect the vacuum hoses to the compressor bypass valve and/EGR valve as noted during removal.
- and) When test running the engine after installation, let the engine idle for approximately one minute to distribute the oil between the turbine shaft bearings.