Removal and installation of a turbocharger

Turbocharger

Withdrawal

1. Disconnect ground wire from battery.

2. Raise the car.

3. After spraying rust remover, unscrew the three nuts that secure the exhaust pipe to the turbocharger flange.

4. Disconnect the turbocharger oil return pipe from the engine block. To do this, loosen the two clamps and, turning, remove the pipeline upwards towards the turbocharger.

5. Lower the car.

6. Disconnect the air line from the air filter and from the turbocharger. Cut the plastic hook and remove the air supply line from the bracket on the radiator shroud.

7. Disconnect the flexible pipe from the crankcase ventilation system from the cylinder head cover.

8. Unscrew the two bolts securing the metal part of the crankcase ventilation pipe from the intake manifold.

9. Remove the air supply line to the turbocharger.

10. Disconnect the air supply elbow from the intake manifold. Plug the open holes in the turbocharger with plugs.


11. Remove the oil line from the turbocharger to the oil cooler.

12. After spraying with a rust remover, unscrew the bolts and nuts securing the exhaust manifold to the engine cylinder head.

13. Remove the intake manifold and turbocharger from the engine cylinder head.

14. Remove the intake manifold gasket.

15. Unscrew the three nuts securing the turbocharger and disconnect it from the exhaust manifold.

16. Unscrew the four nuts securing the exhaust flange to the turbocharger and remove the flange together with the gasket.

Installation

Attention! Always use new nuts to fasten the exhaust manifold and turbocharger.

1. Install the elbow on the exhaust manifold with a new gasket. Screw on the fastening nuts and tighten them to the appropriate torque.

2. Install a new turbocharger flange gasket on the exhaust manifold.

3. Install the turbocharger to the exhaust manifold and tighten the turbocharger mounting nuts to the correct torque.

4. Install a new exhaust manifold gasket on the cylinder head.

5. Attach the oil return pipe fitting to the turbocharger and pull the flexible pipe onto it.

6. Insert the intake manifold and plastic spacer. Install bolts and nuts, but do not tighten them.

7. Put the flexible oil return line on the fitting of the engine block and fix both ends of this line with clamps.

8. Tighten the exhaust manifold bolts and nuts to the correct torque in three steps (see subsection 3.2.1.2.9).

9. Perform the rest of the steps in the reverse order with respect to the removal process.