Tightening torques | |
New turbocharger mounting studs on the exhaust manifold | 9 Nm |
New turbocharger stud on turbocharger | 9 Nm |
Turbocharger fastening nuts | 28 Nm |
Removing
Place the car on a two post lift.
Disconnect the battery.
Remove:
- engine top cover
- air filter housing.
Disconnect:
- hose (1) crankcase ventilation,
- piping between turbocharger and air cooler at point (2).
Remove:
- exhaust gas recirculation solenoid valve,
- air duct between air filter housing and turbocharger,
- engine undertray protection,
- catalytic converter.
Remove:
- turbocharger oil return line (3),
- turbocharger oil supply line,
- fastening nuts (4) turbocharger to exhaust manifold
- turbocharger,
- turbocharger gasket.
Installation
Parts that must be replaced:
- Turbocharger mounting nuts.
- Gasket between exhaust manifold and turbocharger.
- Studs for fastening the exhaust manifold to the turbocharger (in case of turning).
Attention!
- Make sure that no foreign objects get into the turbine or compressor during installation,
- Check that the turbocharger oil outlet line is not partially or completely blocked by carbon deposits. Make sure there is no fuel leakage. Check for leaks, if there are, replace the part.
- Check if the air cooler and engine intake tract are full of oil due to a turbocharger failure. In this case, remove these parts and wash in a washing container or pressure washer, then dry with compressed air.
With gray matting swabs, clean:
- the mating surface of the exhaust manifold,
- the mating surface of the turbocharger in case of its reuse.
Wipe with surface cleaner:
- the mating surface of the exhaust manifold,
- mating surface of the turbocharger in case of its reuse,
- turbocharger air outlet gasket housing,
- mating surface of the exhaust gas cooler bracket on the gearbox side.
Attention! To ensure sealing, mating surfaces must be clean, dry and free of oil (don't touch them with your fingers).
Torque tighten:
- new turbocharger studs on the exhaust manifold (9 Nm),
- new turbocharger stud on turbocharger (9 Nm).
Install:
- a new turbocharger gasket on the exhaust manifold,
- turbocharger.
Use a flat wrench to install new turbocharger mounting nuts without tightening them (the turbocharger must touch the manifold and force is required to turn the wrench).
Torque tighten the turbocharger mounting nuts (28 Nm).
Install:
- turbocharger oil return line,
- turbocharger oil supply line,
- catalytic Converter,
- engine undertray protection,
- air duct between air filter housing and turbocharger,
- exhaust gas recirculation solenoid valve.
Attach:
- pipeline between turbocharger and air cooler,
- crankcase ventilation hose.
Install:
- air filter housing,
- engine top cover.
Connect the battery.
Examination
Disconnect the fuel regulator connector (engine start blocking).
Operate the starter for a few seconds until the oil pressure warning light goes out.
Switch off the ignition.
Connect the fuel regulator connector.
Check for oil leaks.
Connect the diagnostic tool and clear the stored faults.