Turbocharger: Service and Repair

1. Remove negative battery terminal.
2. Remove preheating hose between the plate and air cleaner.
3. Remove intake hose connections at turbo charger. Cover turbo inlet and outlet openings with shop rag or tape to keep dirt and dust out of turbine.
4. Clamp off water hoses to stop coolant flow.
5. Place a container under engine and disconnect the coolant lines from the turbo charger.
6. Remove bellhousing to exhaust pipe clamp.
7. Remove exhaust pipe from turbo charger. Use anti-rust solution on studs before removing nuts.
8. Remove the spark plug wires and upper heat shield.
9. Remove lower heat shield by unscrewing the retaining bolts below the manifold.

Removing Lower Support Bracket:

10. Remove manifold support bracket.
11. Remove the oil supply line bolts, line clamp and banjo bolt at engine block.
12. Loosen the oil return line bolts.
13. Remove all exhaust manifold nuts and washers.
14. Remove exhaust manifold carefully.
15. Remove manifold gaskets and O-ring from oil return line (O-ring may still be in engine block).

Removing Turbo Charger:

16. Remove turbo charger from exhaust manifold.
17. The turbo charger can be replaced as a unit or as a turbine and compressor wheel assembly.
a. If turbo charger is to be replaced as a unit, proceed with step #35.
b. If turbo charger is to be replaced as a turbine and compressor wheel assembly, proceed with next steps.

Removing Turbo Charger Parts:

18. Remove the pressure hose from the nipple.
19. Remove the return oil line.
20. Remove the diaphragm rod clip at the wastegate valve.
21. Remove the wastegate valve housing.

Marking Compressor Housing:

22. Mark the location of the compressor housing to the wastegate diaphragm bracket. Make your marks carefully so the housings will be positioned exactly the same when reassembling the turbo charger.
23. Remove compressor housing bolts (housing must be turned to remove all bolts).
24. Remove compressor housing carefully not to damage the compressor wheel.

Marking Turbine Housing:

25. Mark the location of the turbine housing to the carrier bracket.
26. Remove turbine housing bolts (housing must be turned to remove all bolts).
27. Remove turbine housing carefully not to damage the turbine wheel.
28. Clean and inspect the following parts:
^ Oil supply and return line.
^ Wastegate and housing.
^ Turbine and compressor wheel housing.

Reassembling Turbo Charger:

29. Assemble the turbine and wastegate valve housing with new gasket. Use anti-seize on studs. Torque nuts to:

15 ft.lb (20 Nm)

30. Assemble the turbine housing to wheel assembly with new gasket. Housing must be rotated to install all bolts. Align housing with your marks made when disassembling.
Use anti-seize on threads, tighten bolts evenly all around, then torque the bolts to:

15 ft lb (20 Nm)

31. Install new compressor housing gasket to the wheel assembly.
32. Assemble the compressor housing to wheel assembly. Housing must be rotated to install all bolts. Align housing with your marks made when disassembling.

NOTE: Use new bolts if possible. If no new bolts are available, old bolts can be reused providing, a thread-lock type sealer is used to coat the threads.

Tighten bolts evenly all around, then torque the bolts to:

13 ft lb (18 Nm)

33. Adjust wastegate valve, refer to ADJUSTMENT PROCEDURES.
34. Proceed with step #37.

Transfering Turbo Charger Parts:

35. Transfer nipple, plug, clamp and all other parts to new turbo charger.
36. Adjust wastegate valve (if not preset at factory), refer to ADJUSTMENT PROCEDURES.
37. Install oil return line with new gasket. Check that gasket opening does not restrict oil flow. Start the bolts but do not tighten.

Measuring The Turbo Charger Bolts:

38. Replace the turbo mounting bolts if possible. The bolts can be reused if they are no longer than:

89 mm

Assembling Turbo Charger To Manifold:

39. Coat the threads and contact surfaces (at bolt head) with anti-seize. This is done, so the securing plate does not deform during tightening of bolt.
40. Install the inner securing plate and assemble turbo charger to manifold.
41. Tighten the bolts in sequence (as shown in image) and torque in three stages:

a. 0.7 ft lb (1 Nm)
b. 33 ft lb (45 Nm)
c. additional 45° turn

Installing Outer Plate:

42. Knock the securing plate into position with a hammer or socket.

Bending Inner Plate:

43. Bend the inner securing plate to at least 45° to clear the small gap between bolt head and engine.

New Gaskets:

44. Install new manifold gaskets. The "UT" mark must face the manifold.
45. Install a new O-ring on the oil return pipe. Lubricate O-ring with a little grease.
46. Lift turbo charger and manifold into position. Guide the oil return line into the engine block. Check that O-ring is installed properly.
47. Secure manifold with two new washers and nuts.
48. Tighten oil return line bolts.
49. Fill the turbo charger oil inlet passage with motor oil.
50. Install oil supply line and new gasket. Start, but do not tighten bolts.
51. Install oil supply line banjo bolt at engine block with new gasket, but do not tighten.
52. Install all new manifold washers and nuts. Don't forget the lifting eye. Tighten all exhaust manifold nuts.
53. Tighten oil supply line bolts, clamp and banjo bolt.
54. Install coolant lines with new gaskets and remove the hose clamps.
55. Install heat-shields, spark plug wires and mounting bracket between manifold and engine block.
56. Install exhaust pipe to turbo charger and bellhousing clamp. Use anti-seize and torque exhaust pipe to turbo charger nuts to:

18 ft.lb (25 Nm)

57. Install preheat hose.
58. Install intake air hoses to turbo charger.
59. Connect negative battery terminal.

Building Up Oil Pressure:

60. Disconnect terminal 15 (positive) from ignition coil.
61. Run starter for approx. 30 seconds to build-up oil pressure in the engine and turbo charger.
62. Reconnect terminal 15 at ignition coil.
63. Start engine and let idle for a while before revving up.
64. Check for oil, coolant and exhaust leaks. Correct if necessary.
65. Check coolant level, fill to max. if needed.
66. Check turbo charger pressure, refer to TURBO BOOST PRESSURE TEST under TESTING PROCEDURES.
67. Seal wastegate diaphragm rod with Volvo part #9986408-4 (or equivalent) if seal is not present.