General information
1. The turbocharger is mounted on all diesel engines directly in the exhaust manifold. Lubricant is supplied via the feed oil pipe coming from the oil filter support. The oil drains into the sump via the return oil pipe attached to the side of the cylinder block. The turbocharger unit contains a built-in expansion valve and a vacuum diaphragm actuator, which regulate the boost pressure applied to the intake manifold.
2. The internal components of the turbine rotate at a very high speed - it is very easy to damage it if even the smallest foreign object or dirt gets inside the turbine.
Warning: Before disconnecting oil pipes, wipe the area around them thoroughly to prevent dirt from getting into the turbo. To prevent damage, store removed components in a closed box. To prevent foreign objects and dirt from getting into the system, plug all openings and air intakes with plastic caps. Use only lint-free cloths for wiping.
Removal
3. Apply the handbrake, raise the front of the vehicle and install safety stands. Remove the lower engine cover.
4. If necessary, remove the top engine cover.
5. On models with air conditioning, loosen the axle bolt and tensioner bolt and move the tensioner pulley up to relieve tension on the drive belt. Remove the belt from the crankshaft pulley, compressor pulley and tensioner pulley. Remove the compressor and tie it out of the way as described in chapter 3. Do not disconnect the refrigerant pipes.
6. Loosen the clamps and disconnect the right air intake hose.
7. Loosen the connecting bolt and remove the turbine oil return pipe from the right side of the cylinder block. Plug the holes to prevent dust and dirt from entering.
8. Remove the bolts securing the turbine to the manifold, but leave the two front bolts to support the block.
9. Remove the air cleaner assembly as described in paragraph 2.
10. Loosen the clamps and disconnect the front inlet hose from the turbocharger.
11. Unscrew the connecting nut and disconnect the oil supply pipe from the turbine (Fig. 9.11).
12. Note the installation method of the two vacuum hoses and disconnect them from the boost pressure control unit (Fig. 9.12).
13. Unscrew the nuts securing the turbocharger to the catalytic converter (Fig. 9.13).
14. Unscrew the two mounting bolts and remove the supercharger from the exhaust manifold and neutralizer. Remove the gasket.
Installation
15. Installation - reverse procedure. Please note the following:
- e) Replace gaskets.
- b) Replace all self-locking nuts.
- c) Before connecting the oil feed pipe, fill the turbocharger with clean engine oil from the oil can.
- d) Tighten nuts and bolts to the specified torques.
- d) After starting the engine, let it idle for at least a minute to allow oil to reach the turbine bearings.