Turbocharger- removal and refitting

Note: New gaskets and new tabwashers must be used on refitting.

Removal
1 Disconnect the battery negative lead.

2 Disconnect the turbocharger inlet and outlet air hoses and the hoses from the waste gate actuator and solenoid control valve at their turbocharger connections. Tape over all the disconnected unions and outlets to prevent dirt ingress.

3 Support the exhaust system and disconnect it from the turbocharger exhaust manifold .

4 Disconnect the oil feed union on the top of the turbocharger and the oil return line from underneath the unit (see illustration). Tape over all disconnected pipes and unions.

23.4 Turbocharger oil feed union (A), turbocharger exhaust manifold (B) and
23.4 Turbocharger oil feed union (A), turbocharger exhaust manifold (B) and retaining nuts (C)

5 Bend up the tabwashers, then unscrew the nuts securing the turbocharger to the exhaust manifold. Remove the unit and store it in a clean plastic bag while removed from the car.

Refitting
6 Before refitting the turbocharger ensure that all mating faces are clean and obtain new gaskets and a set of new tabwashers. It is also advisable to renew the engine oil and filter, particularly if a new turbocharger is being fitted or if there was any sign of previous oil contamination.

7 Refitting is a reversal of removal, but bearing in mind the following points: a) Tighten all retaining nuts to the specified torque and secure with the tabwashers.

b) Before connecting the oil feed union, prime the turbocharger bearings by injecting clean engine oil into the union orifice.

c) Crank the engine over on the starter with the ignition LT lead at the coil disconnected until the oil pressure warning light goes out.

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