Turbocharger, Replacing: Removal

Disconnecting the front suspension components

Fig 1: Front Suspension Components

Courtesy of VOLVO CARS OF NORTH AMERICA.

NOTE:

Check that the parking brake is not applied or that the gear selector is in gear or position P.

Remove:

the right-hand front wheel
the center screw for the driveshaft.

Fig 2: Front End Components

Courtesy of VOLVO CARS OF NORTH AMERICA.

NOTE:

Clean the exposed threads outside the nut. Spray using rust solvent before removing the nut.

Remove:

the nut for the ball joint and control arm. Counterhold the ball joint pinion with a Torx wrench so that the boot does not twist

Removing the drive shaft

Fig 3: Identifying Wheel Knuckle, Special Tools 999 7076 And 999 5562

Courtesy of VOLVO CARS OF NORTH AMERICA.

Pull down the control arm. Use: 9997076 and move the wheel knuckle to the side, and install the protective sleeve: 9995562 on the ball joint pin at the same time. Keep it in position using the ball joint nut.

Removing the drive shaft

Fig 4: Drive Shaft

Courtesy of VOLVO CARS OF NORTH AMERICA.

Press out the wheel knuckle and detach the driveshaft from the hub. Take care not to damage the driveshaft boot. Use a tensioner band and pull the strut and spring assembly backwards. Remove the screws for the bearing cap for the driveshaft.

CAUTION:

Do not pull the outer part of the shaft. Doing so could damage the axial stops in the joints.

Pull the driveshaft straight out.

Removing the propeller shaft

Fig 5: Identifying Matchmark On Propeller Shaft CV Joint And Special Tool 999 7057

Courtesy of VOLVO CARS OF NORTH AMERICA.

Mark the propeller shaft CV joint in relation to the bevel gear flange.

Remove the screws for the propeller shaft. Use: 9997057 . Press the shaft's joints together as much as possible. Disconnect the shaft from the bevel gear. Allow the shaft end to rest against the stabilizer bar.

Removing bevel gear

Fig 6: Angle Gear Screws

Courtesy of VOLVO CARS OF NORTH AMERICA.

NOTE:

To prevent oil leakage, position the bevel gear with the bleed hole upward.

Remove the screws, 5 pcs, for the bevel gear. Pull the bevel gear straight out. Then turn it during removal.

Removing components

Fig 7: Identifying Turbocharger Oil Delivery Pipe And The Oil Return Pipe

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove:

the clamp between the turbocharger oil delivery pipe and the oil return pipe.
the screws at the oil return pipe connection to the turbo. Pull the pipe from the cylinder block. Discard the gasket.

NOTE:

Check that the rubber sealing ring comes away with the pipe. Seal the opening in the cylinder block.

Fig 8: Identifying Turbocharger Oil Delivery Pipe And The Oil Return Pipe

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove:

the pipe screws at the connections for the coolant pipes to the turbo
the pipe screws for the oil delivery pipe in the cylinder block
the lower nuts, 2 pcs, for the turbocharger on the exhaust manifold side.
HINT: Use rust solvent or similar
the upper nuts at the turbocharger connection to the manifold.

Removing the turbocharger (TC)

Fig 9: Identifying Turbocharger And Pipe Fittings

Courtesy of VOLVO CARS OF NORTH AMERICA.

Lift off the turbo and place it on the steering gear. Mark up and remove the turbo control hoses. Lower the turbocharger. Discard the old gasket.

Removing manifold and gasket

Fig 10: Identifying Inner Heat Shield And Manifold

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove:

the inner heat shield from the manifold
the nuts and washers holding the manifold against the cylinder head
the manifold
old gasket residue. Clean the gasket surfaces and check that all pin studs are tightened.