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Turbocharger

Turbocharger

If the turbo is to be replaced, perform the steps in Procedure before replacing the turbo .

Warning

There is a risk of burn injuries when working with the exhaust pipe.


To remove



1. Lay out wing covers and remove the battery negative cable.

2. Remove the engine cover, turbo delivery pipe (2 bolts under the wiring harness) together with the connection for the turbocharger and plug the hoses.

3. Disconnect the glow plugs.

4. Remove the induction hose from the turbocharger.

5. Remove the heat shields from the turbocharger, exhaust manifold and starter motor. The lower heat shield bracket for the starter motor only needs to be loosened.


6. Loosen the wiring harness duct from the engine and move it up.

7. Remove the rear centre nut securing the front exhaust pipe to the turbocharger.

8. Raise the car and remove the bottom engine cover.


9. Remove the remaining nuts between the turbocharger and the front exhaust pipe.

10. Loosen the joint between the front exhaust pipe and the intermediate pipe.


11. Remove the front rubber mountings and lower the exhaust pipe.

Important

Work carefully so that the bellows is not bent or cracked.


12. Position a container under the engine and remove the turbocharger oil delivery pipe from the cylinder block.


13. Remove the turbocharger oil return pipe from the cylinder block.

14. Remove the upper bolt for the exhaust manifold support and slacken the lower bolt so that the support can be turned aside. Lower the car.

15. Loosen the vacuum hose from the wastegate diaphragm unit, remove the exhaust manifold and lift it upwards.

16. Remove the turbocharger from the exhaust manifold.


To fit



1. Clean the sealing surfaces, apply Molycote 1000 to the sealing surfaces and on studs as well as fit the turbocharger on the exhaust manifold.

Tightening torque 30 Nm (22 lbf ft).

2. Clean the sealing surfaces, apply Molycote 1000 on the studs and fit the exhaust manifold to the cylinder head using a new gasket and new nuts.

Tightening torque 22 Nm (16 lbf ft).

3. Connect the vacuum hose to the control valve diaphragm box.

4. Apply Molycote 1000 to the turbocharger studs.

5. Raise the car and connect the turbocharger oil return pipe to the cylinder block.

Tightening torque 30 Nm (22 lbf ft).

6. Put the exhaust manifold support back in place and tighten the screws.

Tightening torque 25 Nm (18.5 lbf ft).

7. Connect the turbocharger oil delivery pipe to the cylinder block.

Tightening torque 20 Nm (15 lbf ft).

8. Clean the exhaust pipe joints and replace rubber mountings if needed.


9. Position the front part of the exhaust pipe with a new gasket and fit new nuts.

10. Tighten the joints in the front exhaust pipe loosely making sure the exhaust pipe is not under strain at any point and then tighten it to the turbocharger.

Tightening torque 20 Nm (15 lbf ft).

11. Tighten the exhaust pipe to the intermediate pipe.

Tightening torque 20 Nm (15 lbf ft).

12. Fit the lower cover and lower the car.


13. Tighten the last nut between the turbocharger and the front exhaust pipe.

Tightening torque 20 Nm (15 lbf ft).

14. Loosen the oil delivery pipe connection from the turbocharger and fill the turbocharger oil channel with engine oil. Turn the turbocharger shaft a few times and top up with oil if necessary.


Important

It is very important that the turbocharger contains oil when the engine is started.


15. Tighten the oil delivery pipe connection to the turbocharger.

Tightening torque 20 Nm (15 lbf ft).

16. Fit the wiring harness duct to the engine.

17. Refit the heat shields over the exhaust manifold, turbocharger and the starter motor.

18. Connect the induction hose to the turbocharger.


19. Connect the glow plugs.

20. Fit a new O-ring on the turbo delivery pipe, lubricate the O-ring with acid-free vaseline and refit it.

21. Fit the engine cover.

22. Connect the negative battery cable.

23. Adjust the clock in the car and press 5 times on the remote control lock/unlock button.

24. Check the oil level and top up as necessary.

25. Start the engine and check for leaks.