Volvo Parts Catalog Volvo Accessories Catalog Volvo Technical Articles Volvo Tech Forums
 
  Search our site:    
View Recent Cars  |   Cart  | Project List | Order Status | Help    
Bookmark and Share

Pelican Technical Article:

Turbo Replacement

Jared Fenton

Time:

3 hours3 hrs

Tab:

$700 to $2,000

Talent:

*****

Tools:

Flathead screwdriver, 7mm/10mm/13mm/17mm/19mm,

Applicable Models:

Volvo C30 (2008-10)

Parts Required:

Turbo assembly

Hot Tip:

Soak the mounting nut with penetrant oil prior to starting

Performance Gain:

Better performance

Complementary Modification:

Replace spark plugs

Turbochargers are subject to wear as the mileage increases on your car. This is due to both the harsh temperatures and speeds the turbo works with on a daily basis. The main symptom of a dying turbo is white smoke coming from the exhaust. This is due to oil leaking past the bearings inside the turbo. A quick test is to give the car a healthy step on the gas while parked and in neutral. If white smoke puffs out under load, it's a fair bet you'll need to replace the turbo assembly.

Removing the turbo assembly from the engine may seem a bit daunting due to the limited space you have to work with. The turbo assembly is located directly behind the engine and is a tight squeeze. It is possible to do; it just requires removing a few things beforehand. You'll also need to drain the cooling system to prevent it from spilling all over once the turbo coolant lines are removed. See our article on Coolant Flush and Replacement for more information.

I also recommend unbolting the left side engine mount and supporting the engine with a floor jack. This allows you to pivot the engine forward enough to remove the turbo from the back of the engine. See our article on Replacing Engine Mounts for more information.

Begin by jacking up your car and secure it on jack stands. Then remove the front right wheel and also the front right wheel liner. See our articles on Jacking up Your C30 and Front Wheel Liner Removal for more information.

Shown here is the Borg Warner K04 turbo assembly used on the the Volvo C30.
Figure 1

Shown here is the Borg Warner K04 turbo assembly used on the the Volvo C30. These turbos are unique as the exhaust manifold (green arrow) is cast into the exhaust turbine housing. This makes removing the turbo a little different than most.

Removing the turbo assembly from the engine bay requires you to move the motor forward enough to provide clearance.
Figure 2

Removing the turbo assembly from the engine bay requires you to move the motor forward enough to provide clearance. Support the engine with a floor jack as shown here. While under the car, loosen the hose clamp (green arrow) holding the intercooler hose to the intake tube (yellow arrow) running under the engine. Pull the hose off the intake tube.

Loosen and remove the two 10mm bolts (green arrows) holding the front of the intake tube to the oil pan.
Figure 3

Loosen and remove the two 10mm bolts (green arrows) holding the front of the intake tube to the oil pan.

Loosen the hose clamp (green arrow) holding the turbo hose to the intake tube.
Figure 4

Loosen the hose clamp (green arrow) holding the turbo hose to the intake tube. Pull the hose off the intake tube.

Loosen and remove the 10mm bolt (green arrow) holding the rear of the intake tube to the oil pan.
Figure 5

Loosen and remove the 10mm bolt (green arrow) holding the rear of the intake tube to the oil pan. Remove the intake tube from the oil pan.

You'll now need to remove the upper intake hose (green arrow) leading to the turbo.
Figure 6

You'll now need to remove the upper intake hose (green arrow) leading to the turbo. Accessing the hose clamp is a real pain. You can't even see the clamp. You have to feel for it. Use a 7mm wrench to loosen the clamp (general location of yellow arrow) and eventually pull the intake hose off.

You will now have access behind the engine with the intake tube removed.
Figure 7

You will now have access behind the engine with the intake tube removed. Loosen and remove the four 10mm bolts (green arrows) holding the heat shield to the engine (one bolt on our project car was missing). Carefully lift the heat shield off from around the turbo body (yellow arrow).

From below the engine, loosen and remove the two 19mm banjo bolts (green arrows) securing the coolant feed and return lines to the turbo cartridge.
Figure 8

From below the engine, loosen and remove the two 19mm banjo bolts (green arrows) securing the coolant feed and return lines to the turbo cartridge. Don't forget to replace the copper sealing washers when installing the coolant lines to the new turbo. Now loosen and remove the two T30 Torx screws (yellow arrows) holding the oil return tube to the bottom of the turbo cartridge. Don't forget to replace the gasket as well (purple arrow).

Use a 15mm wrench to loosen and remove the oil breather fitting (green arrow).
Figure 9

Use a 15mm wrench to loosen and remove the oil breather fitting (green arrow). Now loosen and remove the 17mm banjo bolt (green arrow) holding the oil feed line to the turbo cartridge. Be prepared for a little oil to trickle out. Don't forget to replace the copper sealing washers on either side of the banjo bolt. The other side of this hose must also be removed to remove the turbo.

Shown here is the relative location of the other oil feed line connection (yellow arrow).
Figure 10

Shown here is the relative location of the other oil feed line connection (yellow arrow). Unfortunately, it is near impossible to get a picture of. Carefully slide the turbo control valve (green arrow) up and off the mounting bracket to gain access to the oil line fitting. Use a 19mm wrench to loosen and remove the banjo bolt. You'll also want to pull the vacuum line off the compressor bypass valve directly behind the turbo control valve. See our article on Turbo Compressor Bypass Valve Replacement for more information.

Loosen and remove the three 10mm bolts (green arrows) holding the exhaust pipe to the turbo.
Figure 11

Loosen and remove the three 10mm bolts (green arrows) holding the exhaust pipe to the turbo. Pull the exhaust off the end of the turbo.

Now loosen and remove the twelve 13mm nuts (green arrows) holding the turbo assembly to the cylinder head.
Figure 12

Now loosen and remove the twelve 13mm nuts (green arrows) holding the turbo assembly to the cylinder head. It also helps to soak the nuts for a day or two with penetrant oil, as the nuts are likely frozen. Don't be alarmed if you happen to pull a few exhaust studs out of the head. I recommend replacing the stud and nut if this occurs. Once free, slide the turbo assembly off the studs. You'll then want to carefully pivot the motor forward with the left engine mount removed. This will give you enough clearance to pull the turbo assembly up and out. Don't forget to install a new gasket when re-installing the turbo assembly.


Bookmark and Share

  Search our site:    

View Cart & CheckOut | Project List | Order Status |  Help    

 

[Home] [Customer Service] [Shopping Cart] [Project/Wish List]
  [Privacy Statement]  [Contact Us] [About Us] [Shipping] [Careers]

Copyright © Pelican Parts Inc. -    DMCA Registered Agent Contact Page

Page last updated: Wed 12/7/2016 03:04:47 AM