Volvo Cars 1999-05

Turbocharger

Print

Removal & Installation



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust manifold heat shield
     
    Upper air charge pipe
     
    Inner heat shield
     
    Air intake hose
     
    Turbo coolant hoses
     
    Turbo oil lines
     
    Exhaust front pipe and bracket
     
    Red boost pressure hose
     
    White bypass valve hose
     
    Yellow pressure regulator hose
     
    Turbocharger

    Click image to see an enlarged view

    Fig. Turbocharger and exhaust manifold component identification-5-cylinder engines

    Turbocharger and exhaust manifold component identification-5-cylinder engines
     

  6.  

To install:

  1. Install new pin bolts with thread locking compound. Tighten them to 15 ft. lbs. (20 Nm).
  2.  
  3. Install or connect the following:

    Turbocharger and tighten the fasteners to 22 ft. lbs. (30 Nm)
     
    Yellow pressure regulator hose
     
    White bypass valve hose
     
    Red boost pressure hose
     
    Exhaust front pipe and bracket
     
    Turbo oil lines
     
    Turbo coolant hoses
     
    Air intake hose
     
    Inner heat shield
     
    Upper air charge pipe
     
    Exhaust manifold heat shield
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    EVAP canister hose
     
    Air intake hose
     
    Front heated oxygen sensor (HO 2 S) connector
     
    Upper timing belt cover
     
    Heat deflector plate
     
    Crankcase ventilation (CCV) hose from turbocharger (TC) intake
     
    Lower charge air pipe
     
    Transfer case
     
    Catalytic converter
     
    Oil pressure pipe bolt on the TC and place the pipe to one side
     
    Nuts and washers at the junction between the cylinder head and exhaust manifold
     
    Oil return line and seal the opening in the cylinder block
     
    Right halfshaft
     
    Manifold and turbocharger as a unit
     

  6.  

To install:

  1. Install or connect the following:

    Turbocharger and manifold with new gasket, but do not tighten
     
    Oil return line with a new O-ring. Tighten nuts to 108 inch lbs. (12 Nm)
     
    Oil pressure pipe with new gaskets and tighten to 19 ft. lbs (26 Nm)
     

  2.  
  3. Tighten the mounting nuts on the manifold to 27 ft. lbs. (37 Nm).
  4.  
  5. Install or connect the following:

    CCV hose to TC intake, using a new clamp
     
    Heat deflector plate
     
    Transfer case
     
    Catalytic converter
     
    Front HO 2 S connector
     
    Halfshaft
     
    Lower charge air pipe
     
    Upper timing belt cover
     
    Air intake hose
     
    EVAP canister hose
     

  6.  
  7. Fill the cooling system.
  8.  
  9. Start the engine and check for leaks.
  10.  

4-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Air intake assembly
     
    Rear engine cover
     
    Heat shield from the intake manifold
     
    Air intake hoses
     
    Upper charge air pipe
     

  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Heat shield from the firewall
     
    Turbo coolant hoses
     
    Heated oxygen (HO2S) sensors
     
    Front exhaust pipe
     
    Turbo oil lines
     
    Hoses from the turbo control valve
     
    Three-way catalytic converter
     
    Turbocharger
     

  8.  


    Click image to see an enlarged view

    Fig. 4-Cylinder engine turbocharger removal

    4-Cylinder engine turbocharger removal

To install:

  1. Install or connect the following:

    Turbo oil lines with new gasket
     
    Hoses in the turbo control valve
     
    Three-way catalytic converter
     
    Turbocharger and tighten the fasteners to 33 ft. lbs. (45 Nm)
     
    Turbo coolant hoses
     
    Heated oxygen (HO2S) sensors
     
    Front exhaust pipe. Tighten fasters to 18 ft. lbs. (25 Nm).
     
    Upper charge air pipe
     
    Heat shield on firewall
     
    Air intake hoses
     
    Heat shield on intake manifold
     
    Air intake assembly
     
    Engine cover
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Air intake assembly
     
    Rear engine cover
     
    Heat shield from the intake manifold
     
    Air intake hoses
     
    Upper charge air pipe
     

  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Heat shield from the firewall
     
    Turbo coolant hoses
     
    Heated oxygen (HO 2 S) sensors
     
    Front exhaust pipe
     
    Turbo oil lines
     
    Hoses from the turbo control valve
     
    Three-way catalytic converter
     
    Turbocharger

    Click image to see an enlarged view

    Fig. 4-Cylinder engine turbocharger removal

    4-Cylinder engine turbocharger removal
     

  8.  

To install:

  1. Install or connect the following:

    Turbo oil lines with new gasket
     
    Hoses in the turbo control valve
     
    Three-way catalytic converter
     
    Turbocharger and tighten the fasteners to 33 ft. lbs. (45 Nm)
     
    Turbo coolant hoses
     
    Heated oxygen (HO 2 S) sensors
     
    Front exhaust pipe. Tighten fasters to 18 ft. lbs. (25 Nm).
     
    Upper charge air pipe
     
    Heat shield on firewall
     
    Air intake hoses
     
    Heat shield on intake manifold
     
    Air intake assembly
     
    Engine cover
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

6-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Engine stabilizer brace
     
    Air charge pipe
     
    Air intake pipe
     
    Heat deflector plate
     

  4.  
  5. Drain the cooling system
  6.  
  7. Remove or disconnect the following:

    Rear Side Impact Protection System (SIPS) member
     
    Heated oxygen (HO2S) wiring connectors
     
    Catalytic converters
     
    Right half shaft
     
    Turbo coolant pipes
     
    Turbo oil lines
     
    Turbocharger
     

  8.  


    Click image to see an enlarged view

    Fig. Mounting bolt locations for 6-cylinder turbo

    Mounting bolt locations for 6-cylinder turbo

To install:

  1. Install or connect the following:

    Turbocharger and tighten the fasteners to 18 ft. lbs. (25 Nm)
     
    Turbo oil lines. Tighten to 28 ft. lbs. (38 ft. lbs).
     
    Turbo coolant pipes
     
    Catalytic converters with new gaskets. Tighten fasteners to 18 ft. lbs. (25 Nm).
     
    Rear SIPS member. Tighten to 18 ft. lbs. (25 Nm).
     
    Heated oxygen (HO2S) wiring connectors
     
    Right half shaft
     
    Heat deflector plate. Tighten to 18 ft. lbs. (25 Nm).
     
    Air intake pipe
     
    Air charge pipe
     
    Engine stabilizer brace. Tighten the bolts at the suspension turrets to 37 ft. lbs. (50 Nm). Tighten the engine bracket bolt to 59 ft. lbs. (80 Nm).
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Engine stabilizer brace
     
    Air charge pipe
     
    Air intake pipe
     
    Heat deflector plate
     

  4.  
  5. Drain the cooling system
  6.  
  7. Remove or disconnect the following:

    Rear Side Impact Protection System (SIPS) member
     
    Heated oxygen (HO 2 S) wiring connectors
     
    Catalytic converters
     
    Right halfshaft
     
    Turbo coolant pipes
     
    Turbo oil lines
     
    Turbocharger

    Click image to see an enlarged view

    Fig. Mounting bolt locations for 6-cylinder turbo

    Mounting bolt locations for 6-cylinder turbo
     

  8.  

To install:

  1. Install or connect the following:

    Turbocharger and tighten the fasteners to 18 ft. lbs. (25 Nm)
     
    Turbo oil lines. Tighten to 28 ft. lbs. (38 ft. lbs)
     
    Turbo coolant pipes
     
    Catalytic converters with new gaskets. Tighten fasteners to 18 ft. lbs. (25 Nm)
     
    Rear SIPS member. Tighten to 18 ft. lbs. (25 Nm).
     
    Heated oxygen (HO 2 S) wiring connectors
     
    Right halfshaft
     
    Heat deflector plate. Tighten to 18 ft. lbs. (25 Nm)
     
    Air intake pipe
     
    Air charge pipe
     
    Engine stabilizer brace. Tighten the bolts at the suspension turrets to 37 ft. lbs. (50 Nm). Tighten the engine bracket bolt to 59 ft. lbs. (80 Nm)
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

5-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Engine stabilizer brace
     
    Heat shield
     
    Air intake hose
     
    Upper charge air pipe
     
    Turbo coolant hose
     
    Splash guard
     
    Turbo oil lines
     
    Catalytic converter
     
    Right hand halfshaft
     
    Drive shaft
     
    Transfer case
     
    Turbocharger hoses
     
    Turbocharger and exhaust manifold
     

  6.  

To install:

  1. Install the turbo oil lines. Tighten to 19 ft. lbs. (26 Nm).
  2.  
  3. Install the turbocharger and tighten the fasteners as follows:

    Lower nuts where the turbocharger is connected to the manifold to 18 ft. lbs. (25 Nm)
     
    Lower nut where the front exhaust pipe is connected to the turbocharger to 22 ft. lbs. (30 Nm)
     
    Upper nuts where the turbocharger is connected to the manifold to 18 ft. lbs. (25 Nm)
     
    Upper nuts where the front exhaust pipe is connected to the turbocharger to 22 ft. lbs. (30 Nm)
     

  4.  
  5. Install or connect the following:

    Transfer case
     
    Drive shaft
     
    Halfshaft
     
    Catalytic converter
     
    Turbo coolant hoses. Tighten to 19 ft. lbs. (26 Nm).
     
    Air intake hose
     
    Turbo oil lines. Tighten to 28 ft. lbs. (38 Nm).
     
    Splash guard
     
    Upper charge air pipe
     
    Heat shield
     
    Engine stabilizer brace. Tighten the bolts at the suspension turrets to 37 ft. lbs. (50 Nm). Tighten the engine bracket bolt to 59 ft. lbs. (80 Nm).
     

  6.  
  7. Fill the cooling system.
  8.  
  9. Start the engine and check for leaks.
  10.  

 
label.common.footer.alt.autozoneLogo