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323-02 Petrol Injection Equipment > < Fuel Injector - Renew (23 455 0)

Turbocharger Removal and Installation Process

Turbocharger - Remove And Install (23 612 0)Transit 1995 (08/1994-07/2000)
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Removal and Installation

NOTE:

It will be necessary to raise the vehicle during this procedure.
Remove

CAUTION:

Disconnect the battery negative lead.
1. Remove the air cleaner assembly (refer to Operation Number 23 174 0).

CAUTION:

When disconnecting multiplugs do not pull on the wiring; pull on the multiplug body.
2. Disconnect the intake air temperature sensor multiplug.

3. Slacken the clips and remove the air intake pipe.

4. Disconnect the intercooler supply pipe from the turbocharger.

5. Disconnect the turbocharger air intake pipe from the turbocharger.
6. Raise the vehicle.

7. Remove the engine front undershield (if fitted).

8. Remove the engine rear undershield (if fitted).

9. Unscrew the exhaust system to intermediate housing retaining nuts.

10. Detach the exhaust system from the front rubber insulators and secure to one side.

11. Remove the exhaust retaining bracket.
12. Place a drain tray under the turbocharger oil drain pipe.

13. Disconnect the turbocharger oil drain pipe.
14. Lower the vehicle.

15. Disconnect the turbocharger oil supply pipe.

16. Unscrew the EGR valve pipe retaining bolts from the exhaust manifold.
Non‐intercooled variants only

17. Remove the exhaust manifold and turbocharger assembly.
Intercooled variants only

18. Remove the exhaust manifold and turbocharger assembly.
All variants

19. Unscrew the retaining nuts and disconnect the intermediate housing from the turbocharger.

20. Unscrew the retaining nuts and disconnect the exhaust manifold from the turbocharger.
Install
21. Install a new EGR to exhaust manifold pipe gasket.
22. Refit the remaining components in the reverse order.

323-02 Petrol Injection Equipment > < Fuel Injector - Renew (23 455 0)