Replacing The Turbocharger (TC): Finishing

Fig 1: Identifying EGR Valve

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install the EGR valve with a new gasket. Tighten the nuts to 25 Nm  and the Allen screw to 22 Nm  .

Fig 2: Identifying Fuel Filter Nuts And ABS Connector

Courtesy of VOLVO CARS OF NORTH AMERICA.

Applies only to left-hand drive: 

Install the fuel filter holder. Tighten the nuts to 10 Nm  .

Install the ABS switch.

Fig 3: Identifying Hoses

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fill the oil return line with engine oil before installing it.

Install 

• the charge air hose.
• the inlet hose.
• the hose on the EGR valve.
• the hose on the boost pressure control valve.
• the pressure oil line between the turbocharger (TC) and the oil cooler.

Replace the gasket between the pressure oil pipe and the oil cooler.

Tighten the cap nut to the turbocharger (TC) to 30 Nm  and both the screws to the oil cooler to 25 Nm  .

Fig 4: Locating Lower Oil Pipe Bolts

Courtesy of VOLVO CARS OF NORTH AMERICA.

Raise the car.

Install the oil return line from the turbocharger (TC) to the engine. Use a new gasket. Tighten the screws to 30 Nm 

Applies only to right-hand drive cars 

Install the charge air pipe front and rear mountings under the engine. Tighten both to 8 Nm  .

Fig 5: Identifying Collision Protection System

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install 

• the oil drain under the oil filter.
• the three-way catalytic converter (TWC) according to Replacing the three-way catalytic converter (TWC) .

Applies only to right-hand drive cars: 

Install the collision protection system over the oil filter. Tighten to 25 Nm  .

Fig 6: Identifying Engine Stabilizer Brace

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install 

• the torque rod.
• the screws at the suspension turrets. Tighten to 50 Nm  .
• the screw and nut on the torque control arm. Tighten to 80 Nm  .

Check the boost pressure according to Pressure regulator, checking/adjusting .

Check the oil and coolant levels.

Test drive the engine and check for oil and air leakage.