Turbocharger (G2778635): Removal

NOTE:

This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.
This procedure contains illustrations showing certain components removed to provide extra clarity.

Raise and support the vehicle on a suitable 2-post lift.
Refer to: LIFTING
Remove the charge air cooler inlet pipe.
Refer to: CHARGE AIR COOLER INLET PIPE
Remove the electric supercharger.
Refer to: ELECTRIC SUPERCHARGER
Remove the catalytic converter.
Refer to: CATALYTIC CONVERTER
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Remove the turbocharger mounting bolt.
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Disconnect the turbocharger actuator electrical connector.
WARNING: Be prepared to collect escaping coolant.

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- Release the clip.
- Disconnect and remove the coolant pipe.
WARNING: Be prepared to collect escaping coolant.

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- Release the coolant pipe from the clip.
- Remove the bolt.
- Disconnect the 2 coolant pipes from the turbocharger.
- Remove and discard the 2 O-ring seals.
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- Remove the 5 bolts from the turbocharger upper heatshield.
- Release the turbocharger upper heatshield from the 2 clips.
- Remove the turbocharger upper heatshield.
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- Remove the 2 bolts from the turbocharger rear heatshield.
- Release the turbocharger rear heatshield from the clip.
- Remove the turbocharger rear heatshield.
- Release the turbocharger front heatshield from the 2 clips.
- Remove the turbocharger front heatshield.
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- Remove the bolt from the turbocharger inner heatshield.
- Remove the turbocharger inner heatshield.
WARNING: Be prepared to collect escaping oil.

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- Remove and discard the bolt from the oil supply pipe.
- Remove and discard the 2 sealing washers.
WARNING: Be prepared to collect escaping oil.

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- Remove the bolt.
- Remove the oil return pipe.
- Remove and discard the 2 O-ring seals.
NOTE: The spacers and washers will remain captive on the bolts.

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- Use the special tool to remove the 2 bolts, spacers and washers.
  Special Tool(s): JLR-303-1683
- Discard the 2 bolts, spacers and washers.
NOTE: If a new cylinder head is installed 303-1449-02 must be used.

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Install the special tools.

Special Tool(s): 303-1449-01 , 303-1449-02
NOTE: The spacers and washers will remain captive on the bolts.

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- Use the special tool to remove the 11 bolts, spacers and washers.
  Special Tool(s): JLR-303-1683
- Discard the 11 bolts, spacers and washers.
- Remove the turbocharger.
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- Remove the special tools.
  Special Tool(s): 303-1449-01 , 303-1449-02
- Remove and discard the exhaust manifold gasket.
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Use an M8 x 1.5 bottoming tap to clean the threads.