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Timing Belt Idler Pulley Replacement > < Engine Lift Bracket Installation

Astra J

Turbocharger Replacement (2.0L Diesel LBS and LBX)

Removal Procedure

1. Open the hood.
2. Remove the air cleaner outlet rear duct. Refer to Air Cleaner Outlet Rear Duct Replacement .
3. Remove the turbocharger oil feed pipe. Refer to Turbocharger Oil Feed Pipe Replacement .
4. Remove the turbocharger oil return pipe. Refer to Turbocharger Oil Return Pipe Replacement .
5. Disconnect the electrical connector from the wastegate actuator.

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6. Loosen the catalytic converter clamp nut (1) and remove the catalytic converter clamp (2).
7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

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8. Remove the 2 charge air cooler inlet air hose bolts (3).
9. Remove the charge air cooler inlet air hose (2) and hang the hose aside.
10. Remove the charge air cooler inlet air hose gasket (1).
11. Remove the turbocharger wastegate actuator vacuum control solenoid valve hose (4).

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12. Remove the 2 exhaust manifold nuts (2).
13. Lower the vehicle. Refer to Lifting and Jacking the Vehicle .
14. Remove the exhaust manifold nut (1).
15. Remove the turbocharger (4).
16. Remove the turbocharger gasket (3).
17. Clean all of the gasket surfaces.

Installation Procedure


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1. Install a NEW turbocharger gasket (4).
2. Install the turbocharger (5).

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3. Handtighten the 3 NEW exhaust manifold nuts (1, 2, 3) to align the turbocharger to the catalytic converter.

Caution: Refer to Fastener Caution .
4. Install the catalytic converter clamp (2) and tighten the nut (1) to 20 N·m (15 lb ft) .
5. Install the 3 NEW exhaust manifold nuts (1, 2, 3) and tighten in two passes and sequence.

Note:  The sequence is necessary to avoid damages of the gasket between the turbocharger and the exhaust manifold.
6. First pass to:
  6.1 Nut (2) to 15 N·m (11 lb ft) .
  6.2 Nut (1) to 15 N·m (11 lb ft) .
  6.3 Nut (3) to 15 N·m (11 lb ft) .
7. Second pass to:
  7.1 Nut (2) to 28 N·m (21 lb ft) .
  7.2 Nut (1) to 28 N·m (21 lb ft) .
  7.3 Nut (3) to 28 N·m (21 lb ft) .
8. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .

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9. Install the turbocharger wastegate actuator vacuum control solenoid valve hose (4).
10. Install a NEW charge air cooler inlet air hose gasket (1).
11. Install the charge air cooler inlet air hose (2).
12. Install the 2 charge air cooler inlet air hose bolts (3) and tighten to 25 N·m (18 lb ft) .
13. Connect the electrical connector to the wastegate actuator.
14. Install the turbocharger oil return pipe. Refer to Turbocharger Oil Return Pipe Replacement .
15. Install the turbocharger oil feed pipe. Refer to Turbocharger Oil Feed Pipe Replacement .
16. Install the air cleaner outlet rear duct. Refer to Air Cleaner Outlet Rear Duct Replacement .
17. Close the hood.

Timing Belt Idler Pulley Replacement > < Engine Lift Bracket Installation