Removing
Attention. If the turbocharger fails, the gasket residue and excess oil must be carefully removed from the intercooler system before installing a new turbocharger. Failure to remove gasket residue can cause serious damage to the turbocharger and engine after starting. The presence of oil in the air ducts of the turbocharger can cause the engine to over-rev at start-up and, as a result, cause serious damage to the engine.
1. Remove front bumper trim.
2. Remove the air filter outlet duct.
3. Remove the upper intake manifold.
4. Remove the catalytic converter.
5. Remove the exhaust manifold bracket on the right side.
Note. Do not remove the exhaust manifold on the right side.
6. Remove the intercooler outlet duct.
7. Remove the generator.
8. Remove the forced crankcase ventilation pipe from the oil dipstick pipe.
9. Remove the secondary air inlet.
10. Remove the secondary air outlet.
11. Remove the dipstick with guide pipe.
12. Remove the pressure pipe for cooling the turbocharger (1).
13. Loosen fasteners (1) exhaust manifold front heat shield.
14. Remove front heat shield (2) exhaust manifold.
15. Remove three nuts (1) exhaust manifold brackets.
16. Loosen the nuts (1) turbocharger exhaust inlet pipe.
17. Remove the turbocharger exhaust inlet (2).
18. Remove the turbocharger cooling inlet hose.
19. Disconnect the two fasteners of the turbocharger pressure oil lines (2, 6) with gaskets (1, 3).
20. Remove mount (4) pressure oil pipeline of the turbocharger.
21. Remove pressure oil line (5) turbocharger.
22. Remove the mounting bolts (5) turbocharger oil return line.
23. Remove the mounting bolt (3) turbocharger oil return line.
24.Remove the oil return line (4) turbocharger.
25. Remove gasket (1) turbocharger oil return line.
26. Remove seal (2) turbocharger oil return line.
27. Remove the nozzle (1) forced crankcase ventilation.
28. Remove the mounting bolt (2) turbocharger.
29. Remove turbocharger (3).
Installation
1. Install the turbocharger and tighten its fastening bolt to 65 Nm.
2. Install the forced crankcase ventilation pipe.
3. Install new seal (2) turbocharger oil return line.
4. Install a new gasket (1) turbocharger oil return line.
5. Install turbocharger oil return line (4).
6. Install two bolts (5) turbocharger oil return pipe and tighten to 14 Nm.
7. Install bolt (3) turbocharger oil return pipe and tighten to 65 Nm.
8. Install the turbocharger pressure oil pipe (5).
9. Install new gaskets (1, 3) pressure oil pipeline of the turbocharger.
10. Install bolt (4) fastening of the pressure oil pipeline of the turbocharger.
11. Install bolts «banjo» (2, 6) pressure oil line of the turbocharger and tighten to 30 Nm.
12. Install the turbocharger cooling inlet hose.
13. Install a new turbocharger inlet gasket.
14. Install the inlet pipe (2) exhaust gases of the turbocharger.
15. Install nuts (1) fastening the exhaust pipe and tighten to 30 Nm.
16. Install three nuts (1) fastening the exhaust manifold bracket and tighten to 30 Nm.
17. Install front heat shield (2) exhaust manifold.
18. Install fasteners (1) exhaust manifold heat shield and tighten to 10 Nm.
19. Install the pressure pipe for cooling the turbocharger (1) and tighten the M12 bolts to 30 Nm and M14 to 35 Nm.
20. Install the oil dipstick with pipe.
21. Install the secondary air outlet.
22. Install the secondary air inlet.
23. Install the forced crankcase ventilation pipe on the oil dipstick pipe.
24. Install the generator.
25. Install the intercooler outlet duct.
26. Install right exhaust manifold bracket.
27. Install catalytic converter.
28. Install the upper intake manifold.
29. Install an air outlet duct! about the filter.
30. Install the front bumper trim.
31. Install a new oil filter and fill the R engine with fresh engine oil.
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