Turbocharger: Service and Repair

1. Remove negative battery terminal.
2. Disconnect charge air pressure hose and cover opening.

Disconnecting Inlet Hose:

3. Remove the by-pass valve hose.
4. Remove the turbo inlet air hose and cover the opening.

Disconnecting Coolant Lines:

5. Place suitable container under engine to catch the coolant.
6. Clamp off coolant hoses and disconnect coolant line banjo bolts.

Disconnecting Exhaust Pipe From Turbo Charger:

7. Loosen (do not remove) turbo exhaust pipe to catalytic converter bolts. Use anti-rust solution on threads.
8. Remove turbo exhaust pipe from bellhousing bracket and turbo charger. Use anti-rust solution on threads.
9. Disconnect upper oil (supply) line from charger and plug inlet.
On Garrett turbo: Release bracket at front of compressor housing.

Removing Turbo From Manifold:

10. Disconnect charger from manifold.
11. Remove turbo charger with oil return line.
12. Remove oil return line O-ring (may still be in engine block).

Transfering Oil Line:

13. Transfer and clean oil return line. Use new gasket when installing on turbo charger. Apply grease to new O-ring and install on return line.
14. Install new turbo charger with new gasket. Secure charger with a new nut (do not tighten).

Installing Return Line:

15. Press oil return line into position and check that the O-ring is seated correctly.
16. Use a thread locking type compound on manifold to turbo charger studs. Install the three remaining new nuts.

Tightening Turbo Charger:

17. Tighten nuts until contact.
18. Use Volvo tool #5411 (or equivalent) and torque wrench to tighten the nuts, as shown in image, to:

22 ft.lb (30 Nm)

CAUTION: The angle between torque wrench and Volvo tool #5411 (or equivalent) must be 90° to ensure correct torque.

Fitting Oil Line:

19. Remove plug from oil inlet in turbo charger.
20. Fill turbo charger oil inlet with motor oil to lubricate bearings.
21. Install oil supply line with new gaskets.
On Garrett turbo: attach oil line bracket.

Installing Coolant Lines:

22. Install coolant lines with new gaskets.
23. Remove hose clamps.
24. Apply anti-seize to turbo charger to exhaust pipe studs.
25. Install exhaust pipe and start nuts (do not tighten).
26. Install bell housing clamp to exhaust pipe.
27. Tighten exhaust pipe to turbo charger nuts to:

22 ft.lb (30 Nm)

28. Tighten catalytic converter to exhaust pipe bolts to:

18 ft.lb (24 Nm)

29. Attach by-pass hose.
30. Attach the charge air pressure and inlet air hose.
31. Connect negative battery.
32. Fill coolant expansion tank to correct level.
33. Start engine and idle for a while to build up oil pressure in the turbo charger.
34. Check for coolant and oil leaks. Correct if needed.
35. Check boost pressure, refer to TURBO BOOST PRESSURE CHECK under TESTING PROCEDURES.