Removal and installation of a turbocharger (Discovery 3)

Removing

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WARNING: It is forbidden to carry out work on a vehicle standing on only one jack. Be sure to install reliable supports under the car.

Raise and support the vehicle.

2. Open the hood.

Left hand drive vehicles

3.

CAUTION: Do not turn the steering wheel with the lower steering column shaft disconnected as damage to the coil spring and switches located on the steering wheel may occur.

CAUTION: Make sure the steering system is facing straight ahead.

NOTE: Mark the installation position.

Release a bolt of fastening of the bottom shaft of a steering column to the top shaft of a steering column.



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4. Remove the left front wheel.

5. Remove the gearbox protection. Turn out 6 bolts.



6. Remove the engine protection. For more information refer to Motor Protection (76.10.50)


Left hand drive vehicles

7. Remove the radiator panel. Turn out 2 bolts.



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8. Release the lower catalytic converter support insulator.



9. Turn out a bolt of a basic insulator of a transmission. Support the gearbox with a gearbox jack.



10. With the help of another mechanic, remove the transmission support cross member. Remove 4 nuts and remove bolts.




11. With the help of another mechanic, remove the lower catalytic converter.

• Release the clamp.
• Remove three nuts and cut them off.
• Remove the gasket and discard it.

12. Remove the forward heat-insulating screen of system of release.

• Remove three nuts.
• Turn out a bolt.

13. Establish a basic crossbar of a transmission.

• Install, but do not fully tighten at this stage, the 2 gearbox support cross bolts.
• Install, but do not fully tighten at this stage, the transmission support insulator bolt.
• Remove the jack.

14. Remove the heat shield from the differential support bracket. Turn out 2 bolts.



15. Remove the turbocharger support bracket.

• Turn out 2 bolts.
• Loosen the nut.

16. Remove 2 bolts from turbocharger support bracket.



17. Lower the lower turbocharger nut.




18. Remove the top left arm. For more information refer to Upper Arm (60.35.01)

19. Turn the ignition key to position I. Turn the steering wheel so that the head of the steering column lower shaft bolt is visible through the left wheel arch.

20.

CAUTION: Do not turn the steering wheel with the lower steering column shaft disconnected as damage to the coil spring and switches located on the steering wheel may occur.

Loosen and discard the steering column lower shaft bolt.



21. Turn the steering wheel straight ahead. Remove the ignition key.

22. Remove the lower steering column shaft. Loosen and discard the upper steering column lower shaft bolt.



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23. Remove the lower trim of the wing mudguard. Remove 4 clips.



24. Remove the heat shield from the turbocharger. Turn out 2 bolts.



25.

CAUTION: Be sure to plug all open connections to avoid contamination of the system.

Disconnect the turbocharger oil supply line.

• Remove the turbocharger banjo bolt.
• Remove and discard sealing washers.

26.

CAUTION: Be sure to plug all open connections to avoid contamination of the system.

Remove the turbocharger oil return pipe bolt. Disconnect the wire harness clamp.



27. Remove the turbocharger oil return line.

• Turn out 2 bolts.
• Remove the gasket and discard it.
• Remove the O-ring and discard it.

28. Remove the turbocharger support bracket. Turn out 2 bolts.



29. Release clips of final and final pipelines of a turbocharger.



30. Disconnect the turbocharger electrical connector.



31.

WARNING: Be sure to use protective goggles.

CAUTION: Drill only the turbocharger studs.

ATTENTION: Make sure that the depth of the drill does not exceed 14 mm.

Carefully drill out the 2 top turbocharger studs.

• Screw on the 2 upper turbocharger studs.
• Drill a pilot hole in the center of the turbocharger studs; gradually drill out the studs until you get an 8mm hole.

32. With the help of another mechanic, remove the turbocharger. Loosen the lower turbocharger nut.

Installation

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1.

WARNING: Be sure to use protective goggles.

CAUTION: Do not direct the high pressure jet at the skin as this will cause high pressure air can penetrate the subcutaneous tissue and cause serious injury.

WARNING: Maintain high pressure equipment in good condition and inspect and maintain it regularly, paying particular attention to joints and fittings.

Drill two holes in the turbocharger with a diameter of 8 mm, as shown in the figure. Clean the turbocharger and blow it out with compressed air.



2. Install a new turbocharger bottom hole stud.

3. With the help of another mechanic, install the turbocharger.

• Clean the mating surfaces of the turbocharger.
• Align the position of the intake and exhaust pipes of the turbocharger.

4. With the help of another mechanic, tighten the upper nuts and bolts of the turbocharger to 24 Nm.

5. Tighten the lower turbocharger nut to 24 Nm.

6. Connect the turbocharger electrical connector.

7. Tighten the turbocharger inlet and outlet pipe clamps.

8. Install the turbocharger support bracket. Tighten the bolts to 23 Nm.

9. Connect the turbocharger oil supply line.

• Install new sealing washers.
• Tighten the turbocharger oil supply pipe bolt to 30 Nm.

10. Install the turbocharger heat shield. Screw in two bolts.

11. Screw in 2 bolts of a return oil pipeline of a turbocharger.

• Install a new gasket.
• Install a new sealing ring.
• Tighten the 2 bolts to 10 Nm.

12. Install the turbocharger oil return pipe bolt. Connect the wiring harness clamp.

13. Install the wing mudguard lower trim. Install 4 clips.

Left hand drive vehicles

14. Establish the bottom shaft of a steering column.

• Connect the lower steering column shaft to the upper steering column shaft.
• Attach the universal joint to the steering gear.

15. Install, but do not tighten at this stage, a completely new bolt securing the lower steering column shaft to the upper steering column shaft.

16.

CAUTION: Do not turn the steering wheel with the lower steering column shaft disconnected as damage to the coil spring and switches located on the steering wheel may result.

Turn the ignition key to position I. Turn the steering wheel so that the bolt hole of the lower steering column shaft is visible through the left wheel arch.

17. Screw in a bolt of fastening of the lower shaft of a steering column to the steering mechanism. Install a new bolt and tighten to 30 Nm.

18. Turn the steering wheel straight ahead. Remove the ignition key.

19. Tighten the bolt securing the lower shaft of the steering column to the upper shaft of the steering column with a force of 30 Nm.

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20. Install the left upper arm. For more information refer to Upper Arm (60.35.01)

21. Install the 2 turbocharger support bracket bolts. Tighten 2 bolts to 23 Nm.

22. Install the turbocharger support bracket.

• Install the turbocharger support bracket stud.
• Tighten the 2 bolts to 48 Nm.
• Tighten the nut to 25 Nm.

23. Install the differential support bracket heat shield. Screw in 2 bolts and tighten them to 10 Nm.

24. Remove a basic cross-section of a transmission. Support the gearbox with a gearbox jack.

25. Install the exhaust front heat shield.

• Screw on three nuts.
• Screw in the bolt.

26. With the help of another mechanic, install the lower catalytic converter.

• Install new studs and nuts.
• Install a new gasket.
• Tighten the nuts and lower catalytic converter clamp to 48 Nm.

27. Establish a basic crossbar of a transmission.

• Tighten nuts and bolts to 90 Nm.
• Install the gearbox support insulator bolt and tighten to 175 Nm.
• Remove the jack.

28. Attach the lower catalytic converter hanger.

Left hand drive vehicles

29. Install the radiator panel. Tighten the 2 bolts to 10 Nm.

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30. Install engine protection. For more information refer to Motor Protection (76.10.50)

31. Establish protection of a transmission. Tighten the bolts to 10 Nm.

32. Install the left front wheel. Tighten the wheel nuts to 140 Nm.

33. Check the engine oil level, top up if necessary.

34. Close the hood.