Turbocharger: Service and Repair
Turbocharger, replacing
Special tools:
999 7076 Lever 999 7076 Lever
999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket
999 7057 Counterhold 999 7057 Counterhold
951 2953 Cover 951 2953 Cover
951 2957 Coolant Reservoir 951 2957 Coolant Reservoir
Note! The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.
Preparatory work
Removing components
Remove:
- the battery negative lead. See: Battery, disconnecting Battery Disconnecting
- the cross stay between the suspension turrets
- the charge air hose and charge air pipe above the engine. Detach the hose clamp for the turbo's intake pipe at the turbo. Pull the pipe off the connection and move to one side. Mark up the vacuum line for the turbo control valve.
- the vacuum line for the turbo control valve.
- the cable for the catalyst monitor sensor from the clips and the clamps
- the heat shield from the turbo.
Draining coolant
Raise the vehicle. See: Jacking points, body Service and Repair.
Remove the engine undershield from under the engine. Open the nipple on the engine. Drain the coolant into a drain pan. Close the nipple.
Remove:
- the pipe screws for the upper coolant pipe on the turbo and move the coolant pipe to one side
- the screws, 2 x, for the oil delivery pipe on the turbo and disconnect the oil delivery pipe and discard the gasket
- the upper screws, 2 pcs, between the turbo and the exhaust pipe
- the catalyst monitor sensors from the exhaust pipe.
Removal of catalytic converter
Remove the catalytic converter. See: Three-way catalytic converter (TWC), replacing, B5244T5, B5254T2 Service and Repair.
Removal
Disconnecting the front suspension components
Note! Check that the parking brake is not applied or that the gear selector is in gear or position P.
Remove:
- the right-hand front wheel
- the centre screw for the driveshaft.
Note! Clean the exposed threads outside the nut. Spray using rust solvent before removing the nut.
Remove:
- the nut for the ball joint and control arm. Counterhold the ball joint pinion with a Torx wrench so that the boot does not twist
Removing the drive shaft
Pull down the control arm. Use: 999 7076 Lever 999 7076 Lever and move the wheel knuckle to the side, and install the protective sleeve: 999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket on the ball joint pin at the same time. Keep it in position using the ball joint nut.
Removing the drive shaft
Press out the wheel knuckle and detach the driveshaft from the hub. Take care not to damage the driveshaft boot. Use a tensioner band and pull the strut and spring assembly backwards. Remove the screws for the bearing cap for the driveshaft.
Caution! Do not pull the outer part of the shaft. Doing so could damage the axial stops in the joints.
Pull the driveshaft straight out.
Removing the propeller shaft
Mark the propeller shaft CV joint in relation to the bevel gear flange.
Remove the screws for the propeller shaft. Use: 999 7057 Counterhold 999 7057 Counterhold. Press the shaft's joints together as much as possible. Disconnect the shaft from the bevel gear. Allow the shaft end to rest against the stabilizer bar.
Removing bevel gear
Note! To prevent oil leakage, position the bevel gear with the bleed hole upward.
Remove the screws, 5 pcs, for the bevel gear. Pull the bevel gear straight out. Then turn it during removal.
Removing components
Remove:
- the clamp between the turbocharger oil delivery pipe and the oil return pipe.
- the screws at the oil return pipe connection to the turbo. Pull the pipe from the cylinder block. Discard the gasket.
Note! Check that the rubber sealing ring comes away with the pipe. Seal the opening in the cylinder block.
Remove:
- the pipe screws at the connections for the coolant pipes to the turbo
- the pipe screws for the oil delivery pipe in the cylinder block
- the lower nuts, 2 pcs, for the turbocharger on the exhaust manifold side.
Hint: Use rust solvent or similar
- the upper nuts at the turbocharger connection to the manifold.
Removing the turbocharger (TC)
Lift off the turbo and place it on the steering gear. Mark up and remove the turbo control hoses. Lower the turbocharger. Discard the old gasket.
Removing manifold and gasket
Remove:
- the inner heat shield from the manifold
- the nuts and washers holding the manifold against the cylinder head
- the manifold
- old gasket residue. Clean the gasket surfaces and check that all pin studs are tightened.
Installation
Note! For tightening torques, see: Tightening torque Tightening Torque.
Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling Flanged Joint, Assembling.
Installing the manifold/gasket
Install:
- new gaskets
- the manifold. Use new nuts at the manifold. Tighten.
- the inner heat shield.
Fitting of turbo unit
Install:
- the turbo control hoses according to the earlier markings
- the turbo to the manifold with a new gasket
- the upper nuts at the turbo's connection to the manifold. Tighten
- the inlet hose to the inlet manifold on the turbo and tighten the hose clamp
- the screws, 2 pcs, to the oil delivery pipe. Use a new gasket. Tighten.
- the pipe screws for the upper coolant pipe. Tighten.
Raise the vehicle. See: Jacking points, body Service and Repair.
Install:
- the lower screws, 2 pcs, between the turbocharger and manifold. Tighten
- the oil return pipe in the cylinder block with new sealing ring
- the screws, 2 pcs, to the oil return pipe in the turbocharger as well as new gasket. Tighten.
- the pipe screws for the lower coolant pipe. Use new copper washers. Tighten
- the pipe screws for the lower oil delivery pipe in the engine block. Use new copper washers. Tighten
- the clamp between the turbocharger oil delivery pipe and the oil return pipe. Tighten.
Installing the bevel gear
Before installing the bevel gear, lubricate the spline joint between the transaxle and the bevel gear using appropriate grease.
Check that the mating surfaces on the transaxle and bevel gear are clean. Install the bevel gear. Tighten the screws, M10, crosswise to light contact. Tighten.
Installing the propeller shaft
Check that the mating surfaces on the propeller shaft and flange are clean. Install the propeller shaft according to the previous marking. Use new screws. Tighten.
Fitting of catalytic converter
Install the catalytic converter. See Three-way catalytic converter (TWC), replacing, B5244T5, B5254T2 Service and Repair.
Installing the drive shaft and bearing cap on the pilot bearing for the shaft
Tighten the screws.
Installing the drive shaft
Note! Check that the seal on the end of the driveshaft is correctly positioned. See: Seal CV joint housing, replacing Seal CV Joint Housing, Replacing.
Press out the strut and spring assembly.
Align the drive shaft in the hub.
Remove the protective socket, 999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket.
Align the control arm with the ball joint stud. Use: 999 7076 Lever 999 7076 Lever.
Install:
- the nut for the ball joint and control arm. Tighten according to applicable specifications. Counterhold using a Torx wrench to prevent the ball joint boot from turning.
- the centre screw for the driveshaft. Use a new screw. Tighten according to applicable specifications. Use a screwdriver as a counterhold in the brake disc.
Installing wheels
Install the wheel according to: Installing wheels Service and Repair
Installing components
Install:
- the screws for the heat shield above the turbo and screws for the oil delivery pipe. Tighten
- the pipe screws for the upper coolant pipe. Tighten
- the upper charge air pipe. Tighten the screws and clamps
- the cross stay between the suspension turrets. Tighten the screws, 5 pcs.
- the battery negative lead. See: Battery, disconnecting Battery Disconnecting
Finishing
Checks
Top up with coolant. Use filling equipment: 951 2957 Coolant Reservoir 951 2957 Coolant Reservoir and cover: 951 2953 Cover 951 2953 Cover.
Check the oil level in the engine and transaxle. Start the engine and run it until it reaches normal operating temperature.
Check for leakage.
Top up fluids if so required.