Turbocharger 1.8L fuel injected diesel

Withdrawal

1. Disconnect a wire of weight from the accumulator. See Section 414-01 for more information.

2. Remove the air filter. See Section 303-12 for more information.

3. Remove the engine top cover.



4. Disconnect the positive crankcase ventilation hose (PCV) from the valve cover.



5. Remove the air filter outlet pipe.

• 1. Slide the clamp to release the tubing.
• 2. Remove the pipeline.

6. Disconnect the charge air cooler inlet pipe.

• 1. Release the clamp.
• 2. Loosen the nut.

7. Remove the inlet pipe of the charge air cooler.



8. Disconnect the EGR pipe (EGR). Turn out two bolts.



9. Turn out bolts of fastening of cooler EGR to a final collector and remove cooler EGR. Discard the gasket as it is no longer needed.




10. Disconnect the vacuum line of the vacuum diaphragm unit.



11. Remove the EGR pipeline.

12. Remove the catalytic converter. See Section 309-00 for more information.

13. Remove the engine roll stop bolt. Move the engine as far forward as possible.



14. Disconnect the EGR cooler and secure it aside.




15. Disconnect the supply and return oil lines.

• 1. Disconnect the oil supply line. Discard the sealing washers as they are no longer needed.
• 2. Disconnect the oil return line. Discard the O-ring as it is no longer needed.

16. Remove the oil return line from the cylinder block.



17. Lower the car.


18. Turn out the top bolts of fastening of a final collector.



19. Raise and support the vehicle. See Section 100-02 for more information.

20. Remove the catalytic converter support bracket from the cylinder block.



21. Disconnect the turbocharger assembly with the exhaust manifold. Discard the gasket as it is no longer needed.



22. Remove the turbocharger complete with exhaust manifold.

• 1. Move the engine as far forward as possible.
• 2. Remove the turbocharger.

Installation

NOTE: Install a new exhaust manifold gasket.

NOTE: Install a new oil return line O-ring.

NOTE: Install new oil supply line sealing washers.

1. Install the exhaust manifold with turbocharger assembly.

• 1. Move the engine as far forward as possible.
• 2. Install the turbocharger.

2. Establish the bottom bolts of fastening of a final collector.



3. Install the catalytic converter support bracket.



4. Lower the car.

5. Establish the top nuts and bolts of fastening of a final collector.



6. Connect the vacuum line of the vacuum diaphragm unit.



7. Raise and support the vehicle. See Section 100-02 for more information.

8. Connect the return oil line to the cylinder block.



9. Install the supply and return oil lines.

NOTE: Install a new O-ring.

• 1. Install the oil return line.

NOTE: Install new sealing washers.

• 2. Install the oil supply line.

10.

NOTE: Do not tighten bolts at this stage.

Install the EGR cooler mounting bolts (tighten by hand and then loosen 1.5 turns).



11. Lower the car.

12.

NOTE: Do not tighten bolts at this stage.

Install the EGR pipe (hand-tighten the bolts securing the EGR pipe to the EGR valve).



13. Connect the EGR cooler to the exhaust manifold. Install a new gasket between the EGR cooler and the exhaust manifold.



14. Raise and support the vehicle. See Section 100-02 for more information.

15. Tighten the bolts securing the EGR cooler to the cylinder block.



16. Install the engine roll stop bolt.



17. Install the catalytic converter. See Section 309-00 for more information.

18. Tighten the bolts securing the EGR pipe to the EGR valve.



19. Connect the inlet pipeline of the charge air cooler.



20.

CAUTION: Make sure the inside of the charge air cooler intake pipe is clean and free from oil, as this impairs the adhesion between the piping and the charge air cooler. Failure to follow this instruction may result in engine damage.

Install the charge air cooler intake pipe.

• 1. Tighten the clamp.
• 2. Tighten the nut.

21. Install the air filter outlet pipe.

• 1. Install piping.
• 2. Slide the clamp to bring the piping into position.

22. Connect the PCV hose to the valve cover.



23. Install the engine top cover.



24. Install the air filter. See Section 303-12 for more information.

25. Connect a wire of weight to the accumulator. See Section 414-01 for more information.