Turbocharger — removal and installation (Freelander 1)

Dismantling

1. Disconnect the negative battery terminal.

2. Remove the air cleaner filter element.

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

3. Remove the transfer case (IRD).

TRANSFER CASE, REPAIR WORK, Transfer case: models with Td4 engine.

4. Disconnect the vacuum hose and wiring 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 bushing connecting the crankcase ventilation hose to the air cleaner housing.



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



9. Disconnect the connector from the boost pressure control solenoid 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. Unscrew 2 bolts and remove the solenoid valve.



14. Unscrew the 2 bolts securing the turbocharger outlet hose to the cooling system distribution pipe.



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



16. Remove the hatch cover from the heat shield.



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



18. Remove the turbocharger oil supply hollow bolt from the cylinder block and discard the sealing washers.

CAUTION: Always plug the fittings and holes to protect the system from dirt.

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

20. Unscrew the 2 bolts securing the oil drain pipe from the turbocharger to the cylinder block.



21. With the help of a partner, unscrew the 3 bolts and remove the turbocharger. Discard the gasket.



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



23. Unscrew the hollow bolt securing the oil supply pipe and remove the pipe from the turbocharger. Dispose of the sealing washers.

24. Unscrew the bolt of the bracket of the oil drain pipe from the turbocharger.

25. Unscrew the 2 bolts securing the oil drain pipe and remove the pipe from the turbocharger. Discard the gasket.

Installation

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

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

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

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

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

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

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

8. Wipe the oil feed pipe and hollow bolt.

9. Using new sealing washers, install the oil feed pipe onto 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 a torque of 20 Nm.

11. Install the oil drain hose and tighten the clamps.

12. Install the plugs into the holes in the base of the air cleaning filter.

13. Install the hatch cover onto the heat shield.

14. Screw in the bolts securing the turbocharger outlet air hose. Tightening torque for M6 bolts is 10 N·m, for M8 bolts - 20 N·m.

15. Install the turbocharger air outlet hose and tighten the clamps.



16. Install the boost control solenoid valve in place and tighten the mounting bolts to a torque of 10 N·m.

17. Connect the vacuum hoses.

18. Connect the atmospheric hose to the boost control solenoid valve.

19. Connect the connector to the boost control solenoid 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 to the turbocharger, connect the ventilation hose and the air flow/temperature sensor.

23. Secure the air hose with clamps.

24. Secure the vacuum hose and harness with clamps.

25. Install the air cleaner filter element.

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

26. Install the transfer case (IRD).

TRANSFER CASE, REPAIR WORK, Transfer case: models with Td4 engine.

27. Connect the negative battery terminal.