Volvo 240/740/760/780/940/960 1990-1998

Turbocharger

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REMOVAL & INSTALLATION



Before working on the exhaust system, it is a good idea to soak the retaining hardware with a quality rust penetrant prior to attempting to remove them. After the penetrant is applied, wait at least 10-15 minutes to let the penetrant begin to work.

2.3L 4-Cylinder Engine

See Figures 1, 2 and 3

  1. Disconnect the negative battery cable.
  2.  
  3. Remove preheater hose to the air cleaner.
  4.  
  5. Remove the pipe and rubber bellows between the air/fuel control unit and the turbocharger unit.
  6.  
  7. Pull out the crankcase ventilation hose from the pipe.
  8.  
  9. Remove the pipe and pipe connector between the turbocharger unit and the intake manifold.
  10.  

Cover the turbocharger intake and outlet ports to keep dirt out of the system.

  1. Disconnect the exhaust pipe and place aside.
  2.  
  3. Remove the upper heat shield.
  4.  
  5. Remove the brace between the turbocharger unit and the manifold.
  6.  
  7. Remove the lower heat shield by removing the retaining screw under the manifold.
  8.  
  9. Remove the oil pipe clamp, retaining screws on the turbo unit and the pipe connection screw in the cylinder block under the manifold. Do not allow any dirt to enter the oil passages.
  10.  
  11. Remove the manifold retaining nuts and washers. Leave one nut in place to keep the manifold in position.
  12.  
  13. Remove the oil delivery pipe. Cover the opening on the turbo unit.
  14.  
  15. Disconnect the air/fuel control unit by loosening the clamps.
  16.  
  17. Move the unit with the lower section of the air cleaner up to the right side wheel housing. Place a cover over the wheel housing as protection.
  18.  
  19. Remove the remaining nut and washer on the manifold.
  20.  
  21. Lift the assembly forward and up.
  22.  
  23. Remove the manifold gaskets.
  24.  
  25. Disconnect the return oil pipe O-ring from the cylinder block.
  26.  
  27. Disconnect the turbocharger unit from the manifold.
  28.  

To install:

Be sure to use a new gasket for the exhaust manifold and a new O-ring to the return oil pipe. Coat the O-ring with oil prior to installing. Keep everything clean during assembly and use extreme care to keep dirt out of the various turbo inlet and outlet pipes and hoses.

  1. Install the turbocharger on the exhaust manifold and tighten the bolts as follows:
    1. Step 1-7 ft. lbs. (10 Nm)
    2.  
    3. Step 2-30 ft. lbs. (40 Nm)
    4.  
    5. Step 3-Tighten all bolts an additional 120 degrees ( 1 / 3 turn).
    6.  

  2.  
  3. Install the exhaust manifold and turbocharger assembly on the engine.
  4.  
  5. Connect all oil pipes from and to the turbocharger using new O-rings.
  6.  
  7. Install the air/fuel control unit and air cleaner.
  8.  
  9. Install the heat shields, spark plug wires, exhaust pipes, preheater assembly and expansion tank.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Disconnect the wire at terminal 15 (brown) of the ignition coil. Use the ignition key to crank the engine for about 30 seconds. This circulates oil to the turbocharger, providing proper start-up lubrication.
  14.  
  15. Turn the ignition OFF , reconnect the coil wire, start the engine and allow it to idle for a few minutes prior to test driving.
  16.  



Click image to see an enlarged view

Fig. Fig. 1: Turbocharger system component locations-B230FT engine



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Fig. Fig. 2: Disconnect the turbo unit from the exhaust manifold



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Fig. Fig. 3: Lubricating the exhaust manifold bolts with a proper rust penetrant or lubricant aids their installation into the cylinder head. Note the manifold bolt locations

2.3L and 2.4L 5-Cylinder Engines

See Figure 4

  1. Disconnect the negative battery cable.
  2.  
  3. Drain and recycle the engine coolant.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove the heat shield from over the exhaust manifold.
  8.  
  9. Remove the upper air charge pipe and rubber hose from the turbo and move it to one side.
  10.  
  11. Remove the fresh air intake hose and inner heat shield.
  12.  
  13. Disconnect the upper turbo coolant return pipe and clamp off the hose, move it to the side.
  14.  
  15. Disconnect the oil inlet pipe nipple.
  16.  
  17. Raise and safely support the vehicle.
  18.  
  19. Remove or disconnect the following from under side:

    Clamp between the pipes
     
    Oil return pipe
     
    Exhaust pipe bracket and bolt
     
    Exhaust pipe to turbo nut
     
    Exhaust manifold to turbo nuts
     

  20.  
  21. From the top side remove the exhaust pipe to turbo nuts.
  22.  
  23. Disconnect the coolant inlet pipe to the turbo.
  24.  
  25. Remove the turbo/exhaust manifold nuts.
  26.  
  27. Disconnect the following hoses from the turbo:

    red boost pressure
     
    white bypass valve
     
    yellow pressure regulator
     

  28.  
  29. Remove the turbo and the old pin bolts from the exhaust manifold.
  30.  
  31. Coat new O-rings with oil, and install them in the pipes.
  32.  

To install:
  1. Remove the old O-rings from the pipes.
  2.  
  3. Install new pin bolts with threadlocking compound and tighten to 15 ft. lbs. (20 Nm).
  4.  
  5. Install the turbo and connect the red, white, and yellow hoses to it.
  6.  
  7. Install the upper exhaust manifold nuts and tighten them lightly.
  8.  
  9. Working from under the vehicle, install the lower exhaust manifold nuts and tighten them to 18 ft. lbs. (25 Nm).
  10.  
  11. On the top side, tighten the upper exhaust manifold nuts to 18 ft. lbs. (25 Nm).
  12.  
  13. Tighten the exhaust manifold/turbo nuts to 22 ft. lbs. (30 Nm) and check that they are mated properly.
  14.  
  15. Under the vehicle install the oil pipe, grease the O-ring.
  16.  
  17. Install the exhaust pipe bracket bolt.
  18.  
  19. Lower the vehicle and install or connect the following:

    oil inlet pipe
     
    inlet and outlet coolant pipes (make sure the clamps are removed)
     
    fresh air intake hose
     
    inner heat shield
     
    upper air charge pipe
     
    outer heat shield
     

  20.  

Replace the copper coolant pipe and upper oil pipe washers.

  1. Raise the vehicle and remove the clamp from coolant return hose.
  2.  
  3. Connect the negative battery cable.
  4.  
  5. Run the engine to check the boost pressure.
  6.  
  7. Check oil and coolant levels.
  8.  

It may be necessary to reset a fault code after replacing the turbocharger.



Click image to see an enlarged view

Fig. Fig. 4: Turbocharger assembly and related components-2.3L and 2.4L 5-cylinder engines

 
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