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.

    See also:

    Timing belt - removal, refitting and adjustment
    Removal Note: From April 1988 (build code JG) a modified timing belt tensioner incorporating a larger diameter tensioner roller was introduced, and from October 1988 an improved timing belt was u ...

    Using the parking aid - Vehicles With: Front and Rear Parking Aid
    WARNING: The parking aid does not relieve you of your responsibility to drive with due care and attention. Switching the parking aid on and off The parking aid is per default off. To switch the ...

    First aid kit
    Space is provided in the spare wheel well. ...