Turbocharger (TC)

NOTE:

As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.

Removing the turbocharger (TC)

Fig 1: Identifying Engine Compartment Components

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove

the cross stay between the suspension turrets
the heat deflector plate over the turbocharger (TC)
the charge air hose and the charge air pipe above the engine.
Remove the hose clamps for the turbocharger (TC) intake manifold at the air cleaner (ACL) and the turbocharger (TC). Pull off the pipe from the connections. Put the pipe to one side.

Install lock grip pliers on the rubber hose to the coolant inlet pipe for the turbocharger (TC).

Fig 2: Identifying Turbocharger Pipes

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove

the pipe screws where the coolant pipes are connected to the turbocharger (TC).
Bend the outlet pipe upwards. Tie it into place
the pipe screw where the oil pressure pipe connects to the turbocharger (TC)
the upper nuts where the front exhaust pipe is connected to the turbocharger (TC)
the upper nuts where the turbocharger (TC) is connected to the manifold.

Fig 3: Identifying Turbocharger, Oil Pressure Pipe And The Oil Return Line

Courtesy of VOLVO CARS OF NORTH AMERICA.

Raise the car and remove

the splash guard under the engine
the clamp between the turbocharger (TC) oil pressure pipe and the oil return line
the pipe screw where the oil pressure pipe connects to the cylinder block. Lift out the pipe
the screws where the oil return line connects to the turbocharger (TC). Pull the pipe from the cylinder block. Check that the rubber sealing ring comes away with the pipe. Seal the opening in the cylinder block
the lower nut where the front exhaust pipe is connected to the turbocharger (TC)
the lower nuts where the turbocharger (TC) is connected to the manifold.

Fig 4: Removing/Installing Turbocharger

Courtesy of VOLVO CARS OF NORTH AMERICA.

Lower the car

Remove the exhaust pipe from the turbocharger (TC). Hold the pipe to one side and tie it into place.

Lift off the turbocharger (TC). Mark up and remove the turbocharger (TC) hoses.

Place the turbocharger (TC) above the drive shaft and steering gear.

Raise the car.

Remove the turbocharger (TC).

Replacing the manifold and gasket

Fig 5: Identifying Manifold Deflector Plate And Fasteners

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove

heat deflector plate over the manifold
the screws between the support bracket and the cylinder block
the nuts and washers holding the manifold to the cylinder head.

Clean the gasket faces. Check that all studs are tightened.

Install new gaskets

Install the manifold. Use new nuts. Tighten to 25 Nm .

Checking the pressure regulator

When replacing the turbocharger, check the setting of the pressure regulator. See Wastegate valve, adjusting .

Installing the turbocharger (TC)

Fig 6: Identifying Manifold Deflector Plate And Fasteners

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install

the screws between the support bracket and the cylinder block
heat deflector plate over the manifold

Fig 7: Identifying Turbocharger Pipe Connectors

Courtesy of VOLVO CARS OF NORTH AMERICA.

Raise the car

Position the turbocharger (TC) on the drive shaft and steering gear.

Lower the car

Lift up the turbocharger (TC). Install the turbocharger (TC) hoses using the marking made earlier.

Install

the turbocharger (TC) on the manifold
the upper nuts where the turbocharger (TC) is connected to the manifold. Do not tighten yet.
the upper nuts where the front exhaust pipe is connected to the turbocharger (TC). Do not tighten yet.
Raise the car.
the lower nuts where the turbocharger (TC) is connected to the manifold. Tighten to 25 Nm
the lower nut where the front exhaust pipe is connected to the turbocharger (TC). Tighten to 30 Nm
the oil pressure pipe to the connection at the cylinder block. Use a pipe screw and new seal washers .

Fig 8: Identifying Turbocharger Pipes

Courtesy of VOLVO CARS OF NORTH AMERICA.

Lower the car. Install

the pipe screw for the oil pressure pipe to the connection at the turbocharger (TC). Use new seal washers . Tighten to 26 Nm .
Tighten the upper nuts where the turbocharger (TC) is connected to the manifold. Tighten to 25 Nm . Tighten the nuts where the front exhaust pipe connects to the turbocharger (TC). Tighten to 30 Nm
the pipe screws for the coolant pipes. Use new seal washers . Tighten to 26 Nm
the intake pipe between the air cleaner (ACL) and the turbocharger (TC).
Remove the lock grip pliers.

Fig 9: Identifying Turbocharger, Oil Pressure Pipe And The Oil Return Line

Courtesy of VOLVO CARS OF NORTH AMERICA.

Raise the car. Install

the oil return line. Use a new gasket and a new rubber sealing ring .
Remove the seal from the hole in the cylinder block.

Tighten the screw for the oil return line where it connects to the cylinder block. Tighten to 38 Nm
the clamp between the turbocharger (TC) oil pressure pipe and the oil return line
the splash guard under the engine

Fig 10: Identifying Engine Compartment Components

Courtesy of VOLVO CARS OF NORTH AMERICA.

Lower the car. Install

the charge air hose and the charge air pipe above the engine
the heat deflector plate over the turbocharger (TC)
the cross member. Tighten the screws at the suspension turret to 50 Nm and the screw for the engine bracket to 80 Nm .

Carry out a function test

Check the oil and coolant levels.