Engine mechanics - 1.6L (LDE, LLU), 1.8L (2H0) (Turbocharger Replacement): Repair Instructions

Make

Vauxhall

Model

Astra J

Section

Engine mechanics - 1.6L (LDE, LLU), 1.8L (2H0) › Repair Instructions › Turbocharger Replacement

EngineTurbocharger Replacement

Turbocharger Replacement Removal Procedure 1. Remove the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement . 2. Remove the turbocharger oil return hose. Refer to Turbocharger Oil Return Hose Replacement . 3. Remove the catalytic converter. Refer to Catalytic Converter Replacement .            Note:  Release the quick connect fitting (3). Refer to Plastic Collar Quick Connect Fitting Service . 4. Remove the turbocharger coolant return hose (1) from the engine coolant return pipe (5). 5. Remove the turbocharger coolant return hose (1) from the engine coolant thermostat housing (4). 6. Remove the turbocharger coolant return hose (1) from the engine coolant air bleed hose (2) 7. Remove turbocharger coolant feed pipe from turbocharger. Refer to Turbocharger Coolant Feed Pipe Replacement .            8. Loosen the turbocharger oil feed pipe (2) from the turbocharger.   •  Remove the hollow bolt (1).   •  Remove and DISCARD the 2 sealing rings (3).            9. Remove and DISCARD the 9 turbocharger fasteners (1). 10. Remove and DISCARD the turbocharger washer (2). 11. Remove the turbocharger (4). 12. Remove and DISCARD the exhaust manifold gasket (3). Disassemble Procedure Remove the turbocharger coolant return pipe. Refer to Turbocharger Coolant Return Pipe Replacement . Assemble Procedure Install the turbocharger coolant return pipe. Refer to Turbocharger Coolant Return Pipe Replacement . Installation Procedure 1. Clean the exhaust manifold gasket surface.            2. Install a NEW exhaust manifold gasket (3) to the exhaust manifold. Note:  Position the turbocharger oil feed pipe. 3. Install the turbocharger (4). 4. Install a NEW turbocharger washer (2). 5. Install 9 NEW turbocharger fasteners (1). Caution: Refer to Fastener Caution . Caution: Refer to Torque-to-Yield Fastener Caution .            6. Tighten the 9 turbocharger nuts (1) to 2 N·m (18 lb in) in the sequence as shown. 7. Repeat the tightening procedure, tighten the 9 turbocharger nuts (1) to 8 N·m (71 lb in) in the sequence as shown.            8. Position the turbocharger oil feed pipe (2) to the turbocharger. 9. Install the turbocharger oil feed pipe hollow bolt (1) and 2 NEW sealing rings (3) and tighten to 30 N·m (22 lb ft) . 10. Install the turbocharger coolant feed pipe to the turbocharger. Refer to Turbocharger Coolant Feed Pipe Replacement .            Note:  Install the quick connect fitting (3). Refer to Plastic Collar Quick Connect Fitting Service . 11. Install the turbocharger coolant return hose (1) to the engine coolant air bleed hose (2). 12. Install the turbocharger coolant return hose (1) to the engine coolant thermostat housing (4). 13. Install the turbocharger coolant return hose (1) to the engine coolant return pipe (5). 14. Install the catalytic converter. Refer to Catalytic Converter Replacement . 15. Install the turbocharger oil return hose. Refer to Turbocharger Oil Return Hose Replacement . 16. Install the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement . 17. Fill the engine. Refer to Engine Mechanical Specifications . 18. Fill the cooling system. Refer to Cooling System Draining and Filling .

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