Peugeot 308: Removing - refitting : Turbocharger

ESSENTIAL : Observe the safety and cleanliness recommendations .

ESSENTIAL : All personnel carrying out work on a vehicle fitted with traction batteries must have received specific electric vehicle training and be authorised to work on these vehicles (observe the regulations in force in the respective country).

1. Parts which must always be replaced

Description	Quantity
Copper seal (Banjo bolt with integral strainer filter)	2
Seal (Turbocharger lubrication return pipe)	2
Seal (Turbocharger lubrication inlet pipe)	2
Heat shield seal (Turbocharger / Cylinder head)	1
Banjo bolt with integral strainer filter (Turbocharger lubrication pipe )	1

2. Preliminary operations

ESSENTIAL : Wait at least one hour before carrying out any work on the exhaust line.

Place the vehicle on a 2-post lift.

CAUTION : Perform the operations that are required prior to a disconnection of the ancillaries battery .

CAUTION : In the case of a vehicle with 2 batteries, carry out the specific operations for disconnecting and reconnecting the ancillaries batteries.

Disconnect the ancillaries battery or batteries (depending on equipment).

Drain the engine cooling circuit .

Remove :

• The turbocharger air inlet union
• The air inlet pipe
• The catalytic converter

CAUTION : Fit blanking plugs in the openings of the turbocharger .

3. Removing

Slacken and move aside the clip (3).

Uncouple the fuel vapours recirculation pipe (1) (at "a" and "b") (depending on equipment).

Remove :

• The bolts (4)
• The union (2) of the turbocharger air outlet

Disconnect :

• The connector (at "d")
• The connector (at "f")

Unclip the electrical harness (at "c").

Unclip (at "e").

Remove :

• The bolt (6)
• The banjo bolt (5)
• Banjo bolt (7) with integrated strainer filter
• The lubrication inlet pipe (8) of the turbocharger

CAUTION : Plug the openings of the turbocharger assembly.

Remove the nuts (12).

Move aside the turbocharger (10), lubrication return pipe and engine cooling circuit pipes assembly by a few centimetres.

CAUTION : Do not bend or twist the lubrication return pipe when removing the turbocharger assembly (10).

Remove the bolt (11).

Uncouple :

• Engine cooling system pipe (at "j")
• Engine cooling system pipe (at "g")
• The lubrication return pipe (at "h")

Remove :

• The turbocharger (10), lubrication return pipe and engine cooling circuit pipes assembly
• The heat shield seal (9)

N.B. : Operations to be carried out on the bench.

Remove :

• The bolts (14)
• Engine cooling system pipe (13)

Remove :

• The bolts (16)
• The lubrication return pipe (17) of the turbocharger (10)
• The turbocharger (10) lubrication return pipe (17) seal (15)

4. Refitting

CAUTION : Observe the tightening torques.

Tightening torques :

• Engine
• Exhaust line

CAUTION : On refitting, all removed seals must be replaced with new seals.

CAUTION : Do not bend or twist the lubrication return pipe when refitting the turbocharger assembly (10).

Refit :

• The new turbocharger (10) lubrication return pipe seal (15)
• The lubrication return pipe (17) from the turbocharger
• The bolts (16)
• Engine cooling system pipe (13)
• The bolts (14)

Refit :

• The new heat shield seal (9)
• The turbocharger (10), lubrication return pipe (17) and engine cooling circuit pipes (13) assembly
• The nuts (12)

Couple up :

• The lubrication return pipe (17) from the turbocharger (at "h")
• Engine cooling system pipe (13) (at "g")
• Engine cooling system pipe (13) (at "j")

Refit :

• The bolt (11)
• The new turbocharger (10) lubrication inlet pipe (8) seal
• The lubrication inlet pipe (8) of the turbocharger (10)
• The banjo bolt (5)
• New banjo bolt (7) with integrated strainer filter
• The bolt (6)

Reclip (at "e").

Reconnect :

• The connector (at "f")
• The connector (at "d")

Clip the electrical harness (at "c").

Refit :

• The union (2) of the turbocharger air outlet (10)
• The bolts (4)

Tighten the clip (3).

Couple the fuel vapours recirculation pipe (1) (at "a" and "b") (depending on equipment).

5. Additional operations

Refit :

• The catalytic converter
• The air inlet pipe
• The turbocharger air inlet union

Fill and bleed the engine cooling circuit .

Return the vehicle to its wheels.

CAUTION : Perform the operations that are required after reconnecting the ancillaries battery .

CAUTION : In the case of a vehicle with 2 batteries, carry out the specific operations for disconnecting and reconnecting the ancillaries batteries.

Reconnect the ancillaries battery or batteries (depending on equipment).