Turbocharger — removal and installation (Freelander 1)

Dismantling

1. Disconnect "negative" battery terminal.

2. Remove the air cleaner element.

DIESEL ENGINE FUEL SUPPLY, REPAIR WORK, Air cleaner filter element.

3. Remove the transfer case (IRD).

TRANSFER BOX, REPAIRS, Transfer case: models with Td4 engine.

4. Disconnect the vacuum hose and wire harness from the turbocharger air hose.

5. Remove the two clamps securing the turbocharger air hose to the air flow/temperature sensor and remove the hose.

6. Remove the seal between the hose and the air flow/temperature sensor.

7. Remove the sleeve connecting the crankcase ventilation hose to the air cleaner housing.

8. Loosen the 2 clamps and remove the hose from the turbocharger outlet.

9. Disconnect the connector from the vacuum boost pressure control valve.

10. Disconnect the vacuum hose from the turbocharger boost control solenoid valve.

11. Disconnect the atmospheric hose from the turbocharger boost control solenoid valve.

12. Disconnect the vacuum hose from the turbocharger bypass valve.

13. Turn away 2 bolts and remove the electrovacuum valve.

14. Turn away 2 bolts of fastening of an output hose of a turbocharger to a distributive pipe of system of cooling.

15. Loosen, but do not completely remove, the remaining bolt securing the turbocharger outlet hose to the cooling system distribution pipe.

16. Remove the manhole cover from the heat shield.

17. Remove the 3 plugs from the air cleaner filter base.

18. Turn out from the block of cylinders a hollow bolt of supply of oil on a turbocharger and utilize sealing washers.

CAUTION: Always plug fittings and openings to keep dirt out of the system.

19. Loosen 2 clamps and disconnect the oil drain hose from the cylinder block.

20. Turn away 2 bolts of fastening of a pipe of discharge of oil from a turbocharger to the block of cylinders.

21. With the help of a partner, unscrew 3 bolts and remove the TKR. Dispose of the gasket.

22. To facilitate subsequent assembly, mark the position of the oil supply pipe on the TKR.

23. Turn away a hollow bolt of fastening of an oil supply pipe and remove a tube from TKR. Discard sealing washers.

24. Turn away a bolt of an arm of a pipe of drain of oil from TKR.

25. Turn away 2 bolts of fastening of an oil drain tube and remove a tube from TKR. Dispose of the gasket.

Installation

1. Wipe the turbocharger oil drain pipe and mating surfaces.

2. Install the oil drain pipe with a new gasket on the TKR.

3. Tighten the oil drain tube flange bolts to 8 Nm and the tube bracket bolt to 20 Nm.

4. Wipe the turbocharger oil feed tube and mating surfaces.

5. Using new sealing washers, install the oil feed tube, screw in the hollow bolt and tighten it. Tightening torque 22 Nm.

6. Wipe the turbocharger and mating surface on the exhaust manifold.

7. Install the turbocharger on a new gasket and tighten the bolts of its fastening. Tightening torque 50 Nm.

8. Wipe the oil feed tube and hollow bolt.

9. Taking new sealing washers, install the oil supply tube on the cylinder block, screw in the hollow bolt and tighten it. Tightening torque 22 Nm.

10. Screw in the bracket mounting bolts and tighten them to 20 Nm.

11. Put on the oil drain hose and tighten the clamps.

12. Install the plugs in the holes in the air cleaner base.

13. Install the hatch cover on the heat shield.

14. Screw in bolts of fastening of an output air hose of TKR. Tightening torque for M6 bolts - 10 Nm, M8 bolts - 20 Nm.

15. Put on the TKR outlet air hose and tighten the clamps.

16. Install the vacuum boost control valve in place and tighten the mounting bolts to 10 Nm.

17. Attach vacuum hoses.

18. Attach the atmospheric hose to the vacuum boost control valve.

19. Connect the connector to the vacuum boost control valve.

20. Install the ventilation hose fitting.

21. Install the upper gasket on the turbocharger air hose and check the condition of the lower gasket on the turbocharger.

22. Install the hose on the turbocharger, attach the ventilation hose and air flow/temperature sensor.

23. Secure the air hose with clamps.

24. Attach the vacuum hose and harness to the clamps.

25. Install the air cleaner element.