SAAB WIS ONLINE

Turbo

Turbo

Warning

The turbocharger can be hot and great care must be observed.


To remove


1. Remove the battery cover and disconnect the negative battery lead from the battery.


2. Remove the upper engine cover.

3. Disconnect the intake pipe from the mass air flow sensor, turbocharger and camshaft cover.


4. Remove the charge air pipe from the turbocharger and camshaft cover. Bend aside the charge air pipe and plug the pipe and the turbocharger inlet.

5. Remove the wiring mounting from the camshaft cover and the connectors from the glow plugs and mass air flow sensor. Move the wiring out of the way.


6. Remove the heat shields from over the turbocharger and exhaust manifold.


7. Remove the heat shield over the starter motor.

8. Remove the cable duct bolts.

9. To improve access, remove the lower bolt from the engine lifting eye.

10. Remove the upper bolt from the exhaust manifold support. Slacken the lower bolt slightly so that the support can be turned out of the way.


11. Remove the turbocharger's oil delivery pipe.

Important

Take care so as not to crack the bellows on the turbocharger oil delivery pipe.


12. Detach the exhaust pipe from the turbocharger.

13. Remove the turbocharger's oil return pipe from the engine block.


14. Disconnect the vacuum hose from the wastegate diaphragm unit.

15. Remove the exhaust manifold and lift out the turbocharger along with the exhaust manifold.

16. Remove the turbocharger from the exhaust manifold.


To fit


1. If changing the turbocharger: Transfer the oil return pipe to the new turbocharger. Use new seals.

2. Clean the sealing surfaces. Apply 30 20 971 Screw-thread paste to the sealing surfaces and studs. Fit the turbocharger to the exhaust manifold.

Tightening torque 30 Nm (22 lbf ft)

3. Clean the sealing surfaces. Apply 30 20 971 Screw-thread paste to the studs and fit the exhaust manifold to the cylinder head with a new gasket and new nuts.

Tightening torque 22 Nm (16 lbf ft)


4. Connect the vacuum hose to the wastegate diaphragm unit.

5. Apply 30 20 971 Screw-thread paste to the turbocharger studs. Change the gasket between the turbocharger and catalytic converter.

6. Connect the turbocharger's oil return pipe to the engine block.

Tightening torque 30 Nm (22 lbf ft)

7. Attach the exhaust pipe to the turbocharger.

Tightening torque Nm ( lbf ft).

8. Generously fill the turbocharger with oil through the oil delivery line connection. Rotate the turbine while filling.

Important

It is very important that there is oil in the turbine compressor when the engine is started.

Fill the turbo oil inlet and pipe with oil. Spin the compressor wheel several times in order to lubricate the bearings with oil.


9. Connect the oil delivery pipe with new sealing washers to the turbocharger and tighten the connection.

Tightening torque 20 Nm (15 lbf ft)


10. Fit the exhaust manifold support.

11. Fit the cable duct.

12. Fit the heat shields.

Important

Make sure the heat shield is mounted in such a way that it protects both the delivery pipe and the return pipe of the turbocharger. Otherwise, there is a risk that the oil will become too hot.



13. Fit the lower bolt to the engine lifting eye.

14. Fit the wiring mounting to the camshaft cover and plug in the connectors to the glow plugs and mass air flow sensor.


15. Remove the plugs and fit the charge air pipe to the turbocharger and camshaft cover.

16. Fit the intake pipe to the turbocharger, mass air flow sensor and camshaft cover.


17. Fit the upper engine cover.


18. Connect the negative battery cable and fit the battery cover.

19. Since the battery has been disconnected, carry out the following procedures.

20. Check the oil level. Top up if necessary.

21. Connect an exhaust extraction hose, start the engine and check for leaks.