Note: This paragraph only applies to AEB and AJL engines.
General information
1. The turbocharger is mounted directly on the exhaust manifold. Lubrication is supplied through an oil supply tube coming from the oil filter support. Oil is drained into the sump through an oil return pipe attached to the side of the sump. The turbocharger block contains an integral expansion valve and vacuum actuator diaphragm that regulate the boost pressure applied to the intake manifold.
2. The internal components of the turbine rotate at a very high speed - they are very easy to damage if even the slightest foreign object or dirt gets inside the turbine.
Warning: Before disconnecting the oil pipes, carefully wipe the area around them to prevent dirt from getting into the turbine. To prevent damage, store removed components in a closed box. To prevent foreign objects and dirt from entering the system, plug all openings and air intake ducts with caps and plastic plugs. For wiping, use only a rag that leaves no lint.
Withdrawal
3. Apply the handbrake, raise the front of the vehicle and install the safety props (see Jacking up the vehicle and installing jack stands). Remove the lower engine cover.
4. If necessary, remove the engine top cover.
5. On A/C models, loosen the axle bolt and tensioner bolt and move the tensioner pulley up to release tension on the drive belt. Remove the belt from the crankshaft pulleys, compressor and tensioner. Dismantle the compressor, tie it aside so that it does not interfere - see chapter 3. Do not disconnect refrigerant pipes.
6. Remove the turbocharger support bracket.
7. Remove the turbine oil return pipe and remove the gasket.
8. Loosen clamps and disconnect air hoses (sleeves) from the turbocharger.
9. Clamp the turbocharger cooling hoses with suitable clamps. Operate in a different way, drain the coolant - see chapter 1A.
10. Turn away a connecting bolt and disconnect a tube of system of cooling. Remove the pads.
11. Disconnect the vacuum hose from the pressure control valve capsule.
12. Turn away a bolt of fastening of a feeding pipe of cooling to an arm of the valve of a regulator of pressure.
13. Remove the air filter as described in paragraph 2.
14. Remove the engine top cover.
15. Remove the crankcase ventilation tube from the valve cover and heat shield.
16. Turn away two bolts of fastening of the feeding oil tube to the heat-shielding screen and remove the screen.
17. Loosen the clamp and disconnect the cooling system return pipe from the hard pipe on the turbocharger. Leave the rigid tube on the turbocharger.
18. Turn away a nut of connection and disconnect a feeding oil tube. To do this, use two open-end wrenches.
19. Turn away nuts and disconnect a reception pipe of the muffler/catalytic converter from a turbocharger. Move the tube back and remove the gasket.
20. Turn away bolts of fastening of a turbocharger to a final collector. Take the supercharger aside, unscrew the connecting bolt and remove the cooling system feed pipe and gasket. Remove the turbocharger from the vehicle.
Installation
21. Installation - reverse procedure. Pay attention to the following:
- A) Replace gaskets.
- b) Replace all self-locking nuts.
- V) Before connecting the oil supply pipe, fill the turbocharger with clean engine oil from an oil can.
- G) Tighten nuts and bolts to specified torques.
- d) After starting the engine, let it idle so that oil enters the turbine bearings.
- A) Top up and bleed the cooling system as described in chapter 1A.
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