Turbocharger Replacement

Make

Vauxhall

Model

Astra J

Section

Engine mechanics - 1.3L Diesel › Repair Instructions - On Vehicle › Turbocharger Replacement

EngineTurbocharger Replacement

Turbocharger Replacement Removal Procedure 1. Open the hood. 2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection . 3. Remove the engine sight shield. Refer to Engine Sight Shield Replacement .            4. Remove the air cleaner outlet rear duct clamp (2) from the turbocharger. 5. Remove the air cleaner outlet rear duct clamp (3) from the air cleaner outlet front duct. 6. Remove the air cleaner outlet rear duct (1).            7. Remove the 3 turbocharger wastegate actuator vacuum control solenoid valve splash shield nuts (2). 8. Remove the turbocharger wastegate actuator vacuum control solenoid valve splash shield (1).            9. Remove the turbocharger oil feed pipe bolt (2) from the turbocharger (1). 10. Remove the 2 turbocharger oil feed pipe gasket (3). 11. Remove the turbocharger oil feed pipe bolt (5) from the oil filter housing (7). 12. Remove the 2 turbocharger oil feed pipe gasket (6). 13. Remove the turbocharger oil feed pipe (4).            14. Remove the 2 turbocharger oil return hose clamps (3). 15. Remove the turbocharger oil return hose (2) from the turbocharger (1) and the oil filter housing (4). 16. Remove the charge air cooler inlet air pipe gasket (2).            17. Remove 2 charge air cooler inlet air pipe bolts (3). 18. Remove charge air cooler inlet air pipe (4) from the turbocharger (1). 19. Remove catalytic converter. Refer to Catalytic Converter Replacement . 20. Remove the turbocharger. Refer to Turbocharger Removal . Installation Procedure 1. Install the turbocharger. Refer to Turbocharger Installation . 2. Install the catalytic converter. Refer to Catalytic Converter Replacement .            3. Install a NEW charge air cooler inlet air pipe gasket (2). 4. Install the charge air cooler inlet air pipe (4) to the turbocharger (1). Caution: Refer to Fastener Caution . 5. Install the 2 charge air cooler inlet air pipe bolts (3) and tighten to 10 N·m(89 lb in) .            6. Install the turbocharger oil return hose (2) to the turbocharger (1) and the oil filter housing (4). 7. Install the 2 turbocharger oil return hose clamps (3).            8. Install the turbocharger oil feed pipe (4). 9. Install the 2 NEW turbocharger oil feed pipe gasket (6). 10. Install the turbocharger oil feed pipe bolt (5) to the oil filter housing (7) and tighten to 22 N·m (16 lb ft) . 11. Install the 2 NEW turbocharger oil feed pipe gasket (3). 12. Install the turbocharger oil feed pipe bolt (2) to the turbocharger (1) and tighten to 22 N·m (16 lb ft) .            13. Install the turbocharger wastegate actuator vacuum control solenoid valve splash shield (1). 14. Install the 3 turbocharger wastegate actuator vacuum control solenoid valve splash shield nuts (2) and tighten to 9 N·m (80 lb in) .            15. Install the air cleaner outlet rear duct (1). 16. Install the air cleaner outlet rear duct clamp (3) to the air cleaner outlet front duct. 17. Install the air cleaner outlet rear duct clamp (2) to the turbocharger. 18. Install the engine sight shield. Refer to Engine Sight Shield Replacement . 19. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection . 20. Close the hood.

11 Engine