Note: This paragraph applies to AEB and AJL engines only.
General information
1. The turbocharger is mounted directly to the exhaust manifold. Lubricant is supplied via an oil feed pipe coming from the oil filter support. Oil drains into the sump via an oil return pipe attached to the side of the sump. The turbocharger unit contains an integrated expansion valve and a vacuum actuator diaphragm that regulate the boost pressure applied to the intake manifold.
2. The internal components of the turbine rotate at very high speeds - they are very easy to damage 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 turbine. 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 caps and plastic plugs. Use only lint-free cloths for wiping.
Removal
3. Apply the handbrake, raise the front of the car and install safety stands (see Jacking up a car and installing safety supports). 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 and tensioner. Remove the compressor, tie it aside so that it does not interfere - see chapter 3. Do not disconnect the refrigerant pipes.
6. Remove the turbocharger support bracket.
7. Remove the turbine oil return pipe and remove the gasket.
8. Loosen the clamps and disconnect the air hoses (sleeves) from the turbocharger.
9. Clamp the turbocharger coolant hoses with suitable clamps. Alternatively, drain the coolant - see chapter 1A.
10. Loosen the connecting bolt and disconnect the cooling system pipe. Remove the gaskets.
11. Disconnect the vacuum hose from the pressure regulating valve capsule.
12. Unscrew the bolt securing the cooling supply pipe to the pressure regulator valve bracket.
13. Remove the air filter as described in paragraph 2.
14. Remove the top engine cover.
15. Remove the crankcase ventilation tube from the valve cover and heat shield.
16. Loosen the two bolts securing the oil feed pipe to the heat shield and remove the shield.
17. Loosen the clamp and disconnect the coolant return line from the hard line on the turbocharger. Leave the hard line on the turbocharger.
18. Loosen the union nut and disconnect the oil feed pipe. To do this, use two open-end wrenches.
19. Remove the nuts and disconnect the exhaust pipe/catalytic converter from the turbocharger. Move the pipe back and remove the gasket.
20. Remove the turbocharger mounting bolts from the exhaust manifold. Move the turbocharger to the side, remove the connecting bolt and remove the cooling system feed pipe and gasket. Remove the turbocharger from the vehicle.
Installation
21. Installation - reverse procedure. Please note the following:
- a) Replace the 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 to allow oil to flow into the turbine bearings.
- a) Top up and bleed the cooling system as described in chapter 1A.
[This article was copied from an online resource: Audimanual.ru]