Charge Air Pressure With Turbocharger

Charge air pressure with turbocharger

Turbocharger system components, removing & installing

Diesel engine vehicles

Note: Minor deviations may be possible depending on vehicle equipment.





- Noise insulation: Bolted to lock carrier
- Bolt: Qty. 2
- Bolt: Qty. 4
- Lock washer: Qty. 4




- Remove noise insulation panel -arrows-




- Remove left-side noise insulation -arrows-






Note: It is strongly recommended that penetrating oil be applied to all nuts and bolts in the turbo exhaust track prior to attempting removal. Failure to do so may result in seized nuts, and/or broken studs.

WARNING:
Do not re-use fasteners that are worn or deformed in normal use.
Some fasteners are designed to be used only once, and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts, washers, circlips and cotter pins. Always follow recommendations in this manual-replace these fasteners with new parts where indicated, and any other time it is deemed necessary by inspection.

Note: All hose connections are secured with clips. Charge air pressure must be leak free. Replace self-locking nuts.

Note: Some vehicles may require the passenger's side drive shaft to be disconnected from the transmission or removal to get required clearance. Refer to Transmission and Drivetrain - Drive Axles, Bearings and Joints - Axle Shaft Assembly - Service and Repair - Procedures Service and Repair

Observe rules for cleanliness. Vehicle Damage Warnings

Removal

a. Remove airbox assembly with all attached sensors
b. Remove air duct between charge air cooler and intake manifold
c. Remove intake air duct between charge air cooler and turbocharger.
d. Remove oil and coolant lines connected to turbo unit
e. Remove heat shielding, if required for clearance.
f. Disconnect downpipe and catalytic assembly
g. Unbolt exhaust manifold from cylinder head, remove exhaust manifold and turbocharger as an assembly.

Installation

- Installation is reverse of removal.

Editor Note: Oil supply lines for the turbo along with engine oil and filter should be replaced when installing a replacement turbocharger.

- Prior to reinstalling exhaust manifold/turbo assembly, remove any remaining gasket material and ensure that exhaust mounting surfaces are clean. Reinstall with new gasket.
- Before restarting engine be sure to prime turbo oil supply.
Before starting vehicle, the turbocharger oil drain hose should be disconnected from the oil pan and the engine should be turned over with starter until oil is running out of the oil drain hose. This will ensure that the turbo is lubricated before initial start-up.

1. Exhaust manifold
With turbocharger
Only replace as assembly

2. Intake manifold

3. from charge air cooler

4. Gasket
Replace
Coating (beading) toward intake manifold

5. 25 Nm (18 ft lbs)

6. Gasket
Note installation position

7. Bracket
For heat shield (item -9-)

8. Washer

9. Heat shield
Engage in bracket (item -7-)

10. Turbocharger
Only replace as assembly
Removing: remove right drive shaft as transmission

11. Pressure unit
For charge air pressure control valve
Integral part of turbocharger; cannot be replaced

12. From Air Cleaner

13. Gasket
Replace

14. Sealing ring
Replace

15. Oil return pipe
To cylinder block

16. Banjo bolt
25 Nm (18 ft lbs)

17. 15 Nm (11 ft lbs)
18. 40 Nm (30 ft lbs)
19. Bracket
20. 25 Nm (18 ft lbs)

21. Gasket
Replace

22. Front exhaust pipe

23. Connection
24. 10 Nm (7 ft lbs)

25. Oil supply pipe