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Wiring diagrams Section: Turbo-Charging

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Replace Turbocharger Opel Astra H

Turbo-Charging 14 illustrations ~988 words

1. Open bonnet
2. Disconnect battery • Detach earth connection from earth terminal – Slacken nut
3. Remove air intake hose (1) • Undo 2x clamps (2)

4. Disconnect wiring harness plug of oxygen sensor mixture regulation
5. Raise vehicle by half its height
6. Place collecting basin underneath.
7. Drain coolant • Place collecting basin underneath. • Open drain bolt Warning: Coolant system is under pressure. Carefully open coolant expansion tank cover. • Open coolant expansion tank cover. • Collect coolant – Use hose (2) • Close drain bolt

8. Raise vehicle by half its height
9. Where fitted, remove lower engine cover
10. Place collecting basin underneath.
11. Drain engine oil
12. Detach charge air hose (3), intercooler/turbocharger, from turbocharger (1) • Release clamp (2)

13. Remove front exhaust pipe • Detach front exhaust pipe (1) from catalytic converter – Unscrew 3x nuts (2) • Attach flex pipe locking tool

14. Attach exhaust system on left side to underbody using strap • Use a second person • Detach 4x damper rings
15. Remove auxiliary catalytic converter (3) with oxygen sensor mixture regulation (2) and heat shield • Disconnect wiring harness plug of oxygen sensor mixture regulation (1) • Release clamp (4)

16. Detach turbocharger intake pipe (5) • Unscrew 2x bolts (6) • Lower vehicle by its full height • Detach wiring harness – Undo cable tie – Disconnect wiring harness plug for charge pressure control (3) • Detach cylinder head cover vent pipe (1) – Disconnect quick-release fitting • Separate vacuum control for air recirculation control (4) • Detach vacuum line from turbocharger (2) – Release clamp

Note. Seal turbocharger intake connector

Note. Do not bend heat shield too far when removing!

19. Detach turbocharger coolant return hose from turbocharger coolant return line • Release clamp
20. Raise vehicle by its full height
21. Detach turbocharger oil feed line (2) from turbocharger • Unscrew banjo bolt (1)

22. Detach turbocharger coolant supply line (1) • Release clamp (3) • Unscrew bolt (2) • Unscrew banjo bolt (4)

24. Remove oil dipstick guide tube (1) • Detach turbocharger oil return hose from turbocharger • Draw oil dipstick guide tube out of oil pan (2)

Important. To ensure removal of the turbocharger, KM-6001 must be attached as follows:

25. Raise engine with KM-6001-A (1) • Slacken 3x bolts (arrows) in adjusting rails • Insert KM-6001-A – The journals (2) and (7) must sit in the guide holes of the front axle body • Tighten 3x bolts in adjusting rails • Adjust support bearings, front and rear – Raise rear support bearing (6) up to the stop on the guide journal – Raise front support bearing (3) until the underside (4) of the engine damping block aligns with the underside (5) of the engine damping block holder

Note. The guide journal must be seated free from play in the support bearing

26. Lower vehicle by its full height
27. Remove 2x engine transport shackle • Unscrew 2x bolts
28. Detach exhaust manifold with turbocharger from cylinder head • Unscrew and remove 9x nut (arrows) • Carefully remove exhaust manifold with turbocharger

Note. Cover lock carrier and cylinder head with textile cloth to avoid damage!

30. Attach exhaust manifold with turbocharger to cylinder head • Tighten 9x new nuts in the specified tightening sequence 8 Nm • Re-tighten 9x nuts in specified tightening sequence 8 Nm

Note. Use new gasket

Note. Do not tighten

37. Attach turbocharger coolant feed line to oil filter housing • Tighten 2x bolts
38. Attach turbocharger coolant feed line to turbocharger • Tighten banjo bolt 35 Nm
39. Attach turbocharger oil feed line to turbocharger • Tighten banjo bolt 30 Nm
40. Lower vehicle by its full height
41. Attach coolant feed hose to coolant pipe • Attach clamp
42. Attach turbocharger coolant return hose to turbocharger coolant return line • Fasten clamp
43. Install turbocharger heat shield • Screw in 2x bolts

Note. Do not bend heat shield too far when installing!

44. Install dipstick guide tube • Tighten bolt
45. Insert oil dipstick
46. Install turbocharger intake pipe • Attach wiring harness – Attach cable ties – Connect wiring harness plug for charge pressure control • Attach venting line for cylinder head cover – Connect quick release fitting • Connect vacuum control for air recirculation control • Attach vacuum line to turbocharger – Fasten clamp
47. Raise vehicle by its full height
48. Fasten turbocharger intake pipe • Tighten 2x bolts
49. Attach turbocharger oil return line to turbocharger • Fasten clamp
50. Install auxiliary catalytic converter with oxygen sensor mixture regulation • Tighten clamp 7 Nm
51. Attach exhaust system • Use a second person • Loosen strap • Attach 4x damper rings
52. Attach front exhaust pipe to catalytic converter • Detach flex pipe locking tool • Tighten 3x nut 25 Nm

Note. If necessary, release additional catalytic converter and turn it until the exhaust system can be installed

53. Attach charge air hose, intercooler/turbocharger, to turbocharger • Tighten clamp 3.5 Nm
54. Where fitted: Install lower engine cover
55. Lower vehicle by its full height
56. Connect wiring harness plug of oxygen sensor mixture regulation
57. Install air intake hose • Tighten 2x clamp 3.5 Nm
58. Cooling System, Charge and Bleed
59. Top up engine oil
60. Connect battery
61. Program volatile memories
62. Close bonnet

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