Removing
10. Disconnect the negative cable from the battery.
11. Raise and support the machine. Remove the bottom engine cover.
12. Remove the exhaust system. Remove the 2 pins securing the exhaust downpipe to the turbocharger exhaust flange.
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13. Disconnect the oil pipe and turbocharger oil return hose from the cylinder head (be prepared for the fact that this may spill a little oil). Remove the bolts securing the oil tube bracket. Disconnect the return hose from the outlet on the turbocharger and remove it (see pictures).
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14. Unscrew the bolts and remove the rod connecting the lower engine mount to the crosspiece (see photo). When this is done, the engine will move forward a little.
![](https://www.peugeotbook.ru/img/p300/0628.jpg)
15. Lower the machine. Where applicable, remove the vacuum pump along with the drive belt and hoses (see chapter 8).
16. Remove the channel connecting the air cleaner to the intake manifold and the associated crankcase ventilation hoses (see photo).
![](https://www.peugeotbook.ru/img/p300/0629.jpg)
17. Remove the small hose connecting the intake manifold to the injection pump.
18. Loosen the clamps on the hoses connecting the turbocharger to the intake manifold.
19. Using a 6 mm hex wrench, remove the 7 bolts securing the intake manifold. These bolts are very tight and difficult to get to. The hole for the middle bolt is made longer, so that if desired, the middle bolt can simply be loosened.
20. Remove intake manifold. It shares a gasket with the exhaust manifold so that the gasket stays in place (see photo).
![](https://www.peugeotbook.ru/img/p300/0630.jpg)
21. Remove the short hose from the exhaust pipe of the turbocharger (see photo).
![](https://www.peugeotbook.ru/img/p300/0631.jpg)
22. Disconnect the lubrication tube from the top of the turbocharger and remove it. Pay attention to the strainer in the tube (see pictures).
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23. Remove the bolt securing the turbocharger to the manifold (the bolt can be accessed from above) (see photo).
![](https://www.peugeotbook.ru/img/p300/0634.jpg)
24. Raise and support the machine again. Remove the 2 remaining bolts securing the turbocharger to the manifold (see photo). Lower the car.
![](https://www.peugeotbook.ru/img/p300/0635.jpg)
25. Unscrew the bolts and remove the heat shield from the bulkhead of the engine compartment (see photo).
![](https://www.peugeotbook.ru/img/p300/0636.jpg)
26. Pull the turbocharger through the top, exhaust end first (see photo). This is quite difficult to do, but possible. To facilitate care, you can ask the assistant to slightly pull the engine forward.
![](https://www.peugeotbook.ru/img/p300/0637.jpg)
27. If you want to replace the manifold gasket, you must also remove the exhaust manifold.
Inspection
28. Inspect the housing of the removed turbocharger for cracks or other obvious damage.
29. Rotate the turbine or compressor wheel to make sure that the shaft is not damaged and that it does not wobble or bind during rotation. A slight play is normal. Check that the wheel blades are not damaged.
30. In the case of a KKK brand turbocharger, the bypass valve and actuator are combined into one unit and cannot be inspected or tested separately.
31. Oiling of the channels on the exhaust or suction side indicates a possible failure of the turbine shaft seals.
32. The turbocharger cannot be repaired by yourself. If the turbocharger fails, it must be replaced.
Installation
33. Install the turbocharger in reverse order. Pay attention to the following points:
- A. When installing a new turbocharger, the engine oil and oil filter must be changed. Also replace the strainer in the turbocharger oil pipe.
- b. Do not fully tighten grease tube fittings until both ends are connected.
- V. Before starting the engine, the turbocharger lubrication circuit must be bled. To do this, disconnect the cut-off solenoid wire from the fuel pump and crank the engine with the starter 3 times, each time for 10 seconds (see photo).
![](https://www.peugeotbook.ru/img/p300/0638.jpg)
34. After the first start, do not force the engine. Inspect the turbocharger and lube tubes for oil leaks. Switch off the engine and check the oil level.
35. A new turbocharger requires a certain "break-in" period.
Turbocharger oil and return pipes (XUD7/XUD7TE engines) - modification
![](https://www.peugeotbook.ru/img/p300/0639.jpg)
36. Since the end of 1992, on XUD7 / XUD7TE engines, a modification has been made to the design of the turbocharger oil return pipe: instead of a union connection, it now has a flange connection of the type "gasket flange". At the same time, the shape of the turbocharger lubrication tube was changed.