Attention! On 1.9 liter engines, the turbocharger can be removed from the engine installed on the vehicle. On 2.1 liter engines, due to limited space, the turbocharger can only be removed from the engine removed from the vehicle.
Removing
1.9 liter engines
1. Apply the handbrake, raise the front of the vehicle and secure it on stands.
2. Disconnect the exhaust pipe from the turbocharger.
3. Unscrew the nut and remove the oil supply pipe from the top of the turbocharger.
4. Remove the two bolts and disconnect the oil return flange from the turbocharger base. Remove the gasket.
5. Disconnect the inlet and outlet pipe from the turbocharger. Cover the turbocharger opening with a clean cloth.
6. Unscrew the nuts securing the anti-roll bar to the suspension struts.
7. Unscrew the bottom travel stop hanger pinch bolt, then unscrew the nut and bolt attaching the hanger to the bottom frame and remove the hanger.
8. Make marks on the intermediate shaft and steering gear. Unscrew the clamp bolt and nut.
9. Install a suitable piece of wood under the bottom frame to support the bottom frame as it lowers.
10. Remove the four lower frame mounting bolts and lower the lower frame approximately 300mm until the steering hoses are tensioned.
11. Remove the two lower turbocharger mounting bolts.
12. While supporting the turbocharger, unscrew the upper turbocharger mounting bolt and remove the gasket.
13. Lower the turbocharger and remove it from under the vehicle.
2.1 liter engines
1. Remove the power unit.
2. Unscrew the nut and remove the oil supply pipe from the top of the turbocharger.
3. Remove the two bolts and disconnect the oil return flange from the turbocharger base. Remove the gasket.
4. Remove the turbocharger mounting bolt.
5. Remove the three bolts holding the turbocharger to the back of the exhaust manifold (indicated by arrows).
6. Remove the turbocharger from the manifold.
Installation
1. Installation is made in sequence, return to removal.
2. Consider the following points:
- when installing a new turbocharger, change the oil and filter;
- on 1.9 liter engines, do not connect the oil supply pipe until both ends of the pipe are installed;
- on 1.9 liter engines, tighten the lower frame mounting bolts to the appropriate torque;
- on 2.1 liter engines, install the power unit;
- Before starting the engine, circulate the oil by disengaging the engine stop solenoid valve and cranking the engine with the starter several times for 10 seconds.