Turbocharger with exhaust manifold
1 – exhaust manifold; 2 – engine intake pipe; 3 – throttle body; 4 – intake pipe gasket; 5 – intake pipe mounting bolt; 6 – manifold gasket; 7 – washer; 8 – nut; 9 – air filter air duct pipe; 10 – Intercooler air duct pipe; 11 – boost pressure regulator reservoir; 12 – heat-insulating screen; 13 – turbocharger bracket; 14 – bracket mounting bolt; 15 – turbocharger mounting bolt; 16 – sealing ring; 17 – oil drain pipe nipple; 18 – oil drain pipe mounting bolt; 19 – turbocharger oil drain pipe; 20 – tube gasket; 21 – turbocharger; 22 – intake pipe gasket; 23 – exhaust pipe; 24 – oil supply pipe fitting; 25 – oil supply pipe; 26 – tube mounting bolt
The turbocharger can only be removed and replaced as an assembly with the exhaust manifold and boost pressure regulator.
The turbocharger cannot be repaired; if it fails, it must be replaced.
1. Remove the engine splash shield.
2. Remove the right wheel drive (see subsection 7.1.3.7).
3. Remove the axle shaft cover.
4. Disconnect the lower air duct 1 (see figure Bottom charge air duct) from the air intercooler.
5.Disconnect the lower 2 hoses from the turbocharger (see figureTurbocharger (bottom view)) and rear 1 air ducts.
6. Unscrew the union nut and disconnect the pipe 19 from the cylinder block (see the figure Turbocharger with exhaust manifold) draining oil from the turbocharger.
7. Unscrew bolts 14 and 15 and remove bracket 13.
8. Disconnect the vacuum hose 7 (see figure Turbocharger (bottom view)) from the boost pressure regulator.
9. Remove the exhaust pipe (see subsection 6.2 and subsection 6.3).
10. Remove the upper engine cover (see subsection 2.1).
11. Remove the upper air duct 6 (see figure Engine compartment).
12. Remove the EGR tubes between the exhaust manifold and the engine intake pipe.
13. Loosen bolts 18 (see the figure Turbocharger with exhaust manifold) and pick up the phone 19.
14. Unscrew nuts 8 securing the exhaust manifold.
15. Remove the exhaust manifold with the turbocharger by lowering it down.
16. Install the exhaust manifold with the turbocharger in reverse order, replacing all self-locking nuts; fill the turbocharger with engine oil before connecting the oil supply pipe 25 to it.
17. After installing the turbocharger, start the engine and let it idle for at least 1 minute to allow the turbocharger to fill with oil.