Volvo Truck 2003-05

Turbocharger

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Removal & Installation



6-Cylinder Engines

NOTE
The turbocharger for cylinders 1, 2 and 3 is designated turbo 1. The turbo for cylinders 4, 5 and 6 is designated turbocharger 2.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove:

    The splash guard under the engine
     
    The right front wheel and the mudguard at the halfshaft on the right-hand side
     
    The bolt for the fuel line in the oil pan
     
    The support bracket for the bevel gear in the cylinder block
     
    The pipe bolt for the turbocharger oil pressure pipe by the cylinder block.
     
    The connectors for the front heated oxygen sensors. Remove the wiring from the clips and clamps
     
    The brake pipe from the clips on the front SIPS member
     
    The front SIPS member
     
    The three-way catalytic converter from the rubber mountings.
     

  4.  
  5. Connect a hose to the engine coolant drain cock.
  6.  
  7. Drain the coolant into a clean container. Close the cock.
  8.  
  9. Remove:

    The bolt for the engine stabilizer brace mounting on the engine
     
    The engine stabilizer brace between the suspension turrets
     
    The plastic charge air pipe. Place to one side
     
    The plastic intake pipe. Put it to one side.
     

  10.  
  11. Remove from turbo 1:

    The intake and charge air pipes. Seal the openings
     
    The heated oxygen sensor.
     

  12.  


CAUTION
Note the location of the heated oxygen sensor



The heat deflector plate
 
The 3 nuts for the three-way catalytic converter
 


NOTE
use rust solvent



The pipe bolt for the oil pressure pipe
 
The oil pressure pipe
 
The pipe bolts for the coolant pipe. Move the upper coolant pipe and hose to one side
 


NOTE
Position a container underneath for the coolant.



clamp the control pipe for the pressure regulator.
 

  1. Remove from turbo 2:

    The heated oxygen sensor
     
    The heat deflector plate
     
    The 3 nuts for the three-way catalytic converter
     

  2.  


NOTE
Use rust solvent



The upper bolt for the automatic transmission dip stick pipe
 
The intake and charge air pipes. Seal the openings
 
The hose from the pressure regulator
 
The clamps between the coolant pump intake pipe and the turbocharger oil pressure pipe.
 

  1. Raise the car.
  2.  
  3. Remove:

    The oil pressure pipe for turbo 1
     
    The hose from the pressure regulator.
     

  4.  
  5. Lower the car.
  6.  
  7. Remove:

    The pipe bolts for the coolant pipe at turbo 2. Place the lower pipe to one side
     
    move the upper coolant pipe and hose from turbo 2 to one side
     
    The air control pipe for the pressure regulators, 2 bolts
     
    The nuts and washers for the manifold mounting at cylinders 1, 2 and 3.
     

  8.  


NOTE
Use rust solvent or similar. Lift off the manifold/turbocharger.

  1. Remove from turbo 2:

    The bolts for the oil return line
     
    The pipe bolt for the oil pressure pipe
     
    The nuts and washers where the manifold is connected to the cylinder head for cylinders 4, 5 and 6. Carefully lift off the turbocharger and manifold so that the oil pressure pipe is exposed
     

  2.  


NOTE
Do not damage the oil pressure pipe. Lift up and remove the turbocharger and manifold.



Click image to see an enlarged view

Fig. Turbocharger mounting-6-cylinder engine

Turbocharger mounting-6-cylinder engine

To install:

  1. Remove the old gaskets
  2.  
  3. Clean the gasket faces thoroughly
  4.  
  5. Ensure that all the studs are tightened in the cylinder head. Tighten to 15 ft. lbs. (20 Nm).
  6.  
  7. Installing the manifold and turbo 2

    Install new gaskets
     
    Lubricate the studs at the exhaust ports and at the flange on the turbocharger flange to the three-way catalytic converter using paste P/N 1161408, or equivalent.
     
    Lower and install the exhaust manifold and turbocharger.
     

  8.  
  9. Install:

    The washers and new nuts that hold the manifold onto the cylinder head.
     
    The pipe bolt holding the oil pressure pipe to the turbocharger. Use new seal washers. Do not tighten
     
    The bolts for the oil return line.
     
    lower coolant pipe. Use new gaskets.
     

  10.  
  11. Installing the manifold and turbo 1

    Install new gaskets
     
    Lubricate the studs at the exhaust ports and at the flange on the turbocharger flange to the three-way catalytic converter using paste P/N 1161408, or equivalent.
     

  12.  
  13. Install:

    The washers and new nuts that hold the manifold onto the cylinder head.
     
    The pipe for pressure regulator control
     
    The upper coolant pipe and hose to turbo 2. Use new seal washers.
     
    The upper coolant pipe and hose to turbo 1. Use new seal washers.
     

  14.  
  15. Install the three-way catalytic converter on the turbocharger. Use new nuts. Lubricate the studs using copper paste 116 1408, or equivalent.
  16.  
  17. Installing components at turbo 1

    The oil return line. Use a new gasket
     
    The hose for the pressure regulator
     
    The oil pressure pipe
     
    The pipe bolt for the connection between the oil pressure pipes and the cylinder block. Use new seal washers. Do not tighten.
     

  18.  
  19. Installing components at turbo 2
  20.  
  21. Lower the car. Tighten the pipe bolt for the oil pressure pipe.

    The charge air pipe. Align and tighten the clamp
     
    The intake manifold. Align and tighten the clamp
     

  22.  


NOTE
Remove the previously installed seals



The upper bolt securing the automatic transmission dip stick pipe to the engine. Tighten the lower bolt
 
The heat deflector plate above the turbocharger
 
The heated oxygen sensor
 
The clamps between the coolant pump intake pipe and the turbocharger oil pressure pipe
 

  1. Installing components at turbo 1

    The pipe bolt for the oil pressure pipe. Use new seal washers
     
    The heat deflector plate above the turbocharger
     
    The heated oxygen sensor in its original position
     

  2.  


CAUTION
Ensure that the probes are in the same position to prevent diagnostic trouble codes (DTCs) being stored



The charge air pipe. Align and tighten the clamp
 
The intake manifold. Install but do not tighten the clamp
 


NOTE
Remove the previously installed seals.

  1. Install:

    The pipe bolt for the oil pressure pipe at the connection in the cylinder block
     
    The support bracket for the bevel gear. First screw 4 M10 bolts in to the cylinder block to contact. Then tighten 2 M10 bolts in the bevel gear. Then tighten the M10bolts in the cylinder block.
     
    The bolt for the fuel line in the oil pan
     
    The splash guard at the halfshaft
     
    Hook the three-way catalytic converter into the rubber mounting
     
    The front SIPS member. Press the brake pipe into place. Connect the wiring for the heated oxygen sensors. Secure the wiring as before
     
    The right front wheel
     
    The plastic intake pipe
     
    The plastic charge air pipe
     
    The vacuum hoses for the purge valve and turbocharger control valve
     
    The engine stabilizer brace
     

  2.  
  3. Fill with coolant.
  4.  
  5. Warm up the engine until the thermostat opens.
  6.  
  7. Check:

    The engine for leaks
     
    The coolant level
     

  8.  
  9. Install the lower engine cover.
  10.  


NOTE
The turbocharger for cylinders 1, 2 and 3 is designated turbo 1. The turbo for cylinders 4, 5 and 6 is designated turbocharger 2.

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

    The splash guard under the engine
     
    The right front wheel and the mudguard at the halfshaft on the right-hand side
     
    The bolt for the fuel line in the oil pan
     
    The support bracket for the bevel gear in the cylinder block
     
    The pipe bolt for the turbocharger oil pressure pipe by the cylinder block.
     
    The connectors for the front heated oxygen sensors. Remove the wiring from the clips and clamps
     
    The brake pipe from the clips on the front SIPS member
     
    The front SIPS member
     
    The three-way catalytic converter from the rubber mountings.
     

  4.  
  5. Connect a hose to the engine coolant drain cock.
  6.  
  7. Drain the coolant into a clean container. Close the cock.
  8.  
  9. Remove:

    The bolt for the engine stabilizer brace mounting on the engine
     
    The engine stabilizer brace between the suspension turrets
     
    The plastic charge air pipe. Place to one side
     
    The plastic intake pipe. Put it to one side.
     

  10.  
  11. Remove from turbo 1:
    CAUTION
    Note the location of the heated oxygen sensor


    NOTE
    use rust solvent


    NOTE
    Position a container underneath for the coolant.



    The intake and charge air pipes. Seal the openings
     
    The heated oxygen sensor.
     



    The heat deflector plate
     
    The 3 nuts for the three-way catalytic converter
     



    The pipe bolt for the oil pressure pipe
     
    The oil pressure pipe
     
    The pipe bolts for the coolant pipe. Move the upper coolant pipe and hose to one side
     



    clamp the control pipe for the pressure regulator.
     

  12.  
  13. Remove from turbo 2:
    NOTE
    Use rust solvent



    The heated oxygen sensor
     
    The heat deflector plate
     
    The 3 nuts for the three-way catalytic converter
     



    The upper bolt for the automatic transaxle dip stick pipe
     
    The intake and charge air pipes. Seal the openings
     
    The hose from the pressure regulator
     
    The clamps between the coolant pump intake pipe and the turbocharger oil pressure pipe.
     

  14.  
  15. Raise the car.
  16.  
  17. Remove:

    The oil pressure pipe for turbo 1
     
    The hose from the pressure regulator.
     

  18.  
  19. Lower the car.
  20.  
  21. Remove:
    NOTE
    Use rust solvent or similar. Lift off the manifold/turbocharger.



    The pipe bolts for the coolant pipe at turbo 2. Place the lower pipe to one side
     
    move the upper coolant pipe and hose from turbo 2 to one side
     
    The air control pipe for the pressure regulators, 2 bolts
     
    The nuts and washers for the manifold mounting at cylinders 1, 2 and 3.
     

  22.  
  23. Remove from turbo 2:
    NOTE
    Do not damage the oil pressure pipe. Lift up and remove the turbocharger and manifold.



    The bolts for the oil return line
     
    The pipe bolt for the oil pressure pipe
     
    The nuts and washers where the manifold is connected to the cylinder head for cylinders 4, 5 and 6. Carefully lift off the turbocharger and manifold so that the oil pressure pipe is exposed
     



    Click image to see an enlarged view

    Fig. Turbocharger mounting-6-cylinder engine

    Turbocharger mounting-6-cylinder engine
  24.  

To install:

  1. Remove the old gaskets
  2.  
  3. Clean the gasket faces thoroughly
  4.  
  5. Ensure that all the studs are tightened in the cylinder head. Tighten to 15 ft. lbs. (20 Nm).
  6.  
  7. Installing the manifold and turbo 2

    Install new gaskets
     
    Lubricate the studs at the exhaust ports and at the flange on the turbocharger flange to the three-way catalytic converter using paste P/N 1161408, or equivalent.
     
    Lower and install the exhaust manifold and turbocharger.
     

  8.  
  9. Install:

    The washers and new nuts that hold the manifold onto the cylinder head.
     
    The pipe bolt holding the oil pressure pipe to the turbocharger. Use new seal washers. Do not tighten
     
    The bolts for the oil return line.
     
    lower coolant pipe. Use new gaskets.
     

  10.  
  11. Installing the manifold and turbo 1

    Install new gaskets
     
    Lubricate the studs at the exhaust ports and at the flange on the turbocharger flange to the three-way catalytic converter using paste P/N 1161408, or equivalent.
     

  12.  
  13. Install:

    The washers and new nuts that hold the manifold onto the cylinder head.
     
    The pipe for pressure regulator control
     
    The upper coolant pipe and hose to turbo 2. Use new seal washers.
     
    The upper coolant pipe and hose to turbo 1. Use new seal washers.
     

  14.  
  15. Install the three-way catalytic converter on the turbocharger. Use new nuts. Lubricate the studs using copper paste 116 1408, or equivalent.
  16.  
  17. Installing components at turbo 1

    The oil return line. Use a new gasket
     
    The hose for the pressure regulator
     
    The oil pressure pipe
     
    The pipe bolt for the connection between the oil pressure pipes and the cylinder block. Use new seal washers. Do not tighten.
     

  18.  
  19. Installing components at turbo 2
  20.  
  21. Lower the car. Tighten the pipe bolt for the oil pressure pipe.
    NOTE
    Remove the previously installed seals



    The charge air pipe. Align and tighten the clamp
     
    The intake manifold. Align and tighten the clamp
     



    The upper bolt securing the automatic transaxle dip stick pipe to the engine. Tighten the lower bolt
     
    The heat deflector plate above the turbocharger
     
    The heated oxygen sensor
     
    The clamps between the coolant pump intake pipe and the turbocharger oil pressure pipe
     

  22.  
  23. Installing components at turbo 1
    CAUTION
    Ensure that the probes are in the same position to prevent diagnostic trouble codes (DTCs) being stored


    NOTE
    Remove the previously installed seals.



    The pipe bolt for the oil pressure pipe. Use new seal washers
     
    The heat deflector plate above the turbocharger
     
    The heated oxygen sensor in its original position
     



    The charge air pipe. Align and tighten the clamp
     
    The intake manifold. Install but do not tighten the clamp
     

  24.  
  25. Install:

    The pipe bolt for the oil pressure pipe at the connection in the cylinder block
     
    The support bracket for the bevel gear. First screw 4 M10 bolts in to the cylinder block to contact. Then tighten 2 M10 bolts in the bevel gear. Then tighten the M10 bolts in the cylinder block.
     
    The bolt for the fuel line in the oil pan
     
    The splash guard at the halfshaft
     
    Hook the three-way catalytic converter into the rubber mounting
     
    The front SIPS member. Press the brake pipe into place. Connect the wiring for the heated oxygen sensors. Secure the wiring as before
     
    The right front wheel
     
    The plastic intake pipe
     
    The plastic charge air pipe
     
    The vacuum hoses for the purge valve and turbocharger control valve
     
    The engine stabilizer brace
     

  26.  
  27. Fill with coolant.
  28.  
  29. Warm up the engine until the thermostat opens.
  30.  
  31. Check:

    The engine for leaks
     
    The coolant level
     

  32.  
  33. Install the lower engine cover.
  34.  

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
     
    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 18 ft. lbs. (25 Nm) on models without a gasket; 27 ft. lbs. (37 Nm) on models with a gasket.
     
    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.  

8-Cylinder Engines

Turbocharger package is not currently available for the 8-Cylinder Engine.

 
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