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Turbo

Turbo

If the turbo must be replaced, carry out Before replacing the turbo .

To remove



1. Open the drain plug and drain the coolant. Unscrew the expansion tank cap to speed this up.

2. Raise the car and remove the air pipe and hose between the turbocharger and charge air cooler.

3. Undo the joint between the front exhaust pipe and intermediate pipe and slacken the bolt securing the exhaust pipe to the mounting on the engine.

4. Detach the front exhaust pipe from the turbocharger and suspend the pipe in a way that avoids damaging the oxygen sensor lead.

5. Break the lead seal and remove the circlip on the boost pressure control valve.


6. Remove the turbocharger stay and detach the oil return pipe. Plug the pipe with a rag or the like.

7. Detach the oil pipe at the oil filter and lower the car.

8. Detach the solenoid valve hoses, noting how they are routed.

9. Remove the intake hose with bypass hose, undo the boost pressure control valve's diaphragm box nuts and remove the intake manifold with crankcase ventilation pipe.


10. Detach the turbocharger's oil pipe and remove the lower coolant pipe.


11. Remove the upper coolant pipe retaining bolt from the turbocharger.

12. Remove the turbocharger.


To fit



1. Clean all sealing surfaces and fit the turbocharger.

Tightening torque: 22 Nm (16 lbf ft)

2. Fit the coolant pipes and turbocharger oil pipe.

Important

To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressures, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 30 15 815 Cleaning agent to wipe clean inside the ends of the hoses. Clean also the connecting pieces. If hose clips are rusty or damaged, they must be replaced with new ones to maintain the correct clamping force.


3. Refit the turbocharger's intake manifold with crankcase ventilation pipe. Tighten the boost pressure control valve's diaphragm box nuts and attach the hose to the turbocharger housing.

4. Fit the intake hose with bypass hose and raise the car.


5. Attach the oil pipe at the oil filter and fit the return oil pipe.

6. Fit the wastegate circlip and refit the stay between the turbocharger and cylinder block.

7. Lubricate the three studs on the turbocharger with Molycote 1000 and fit the front exhaust pipe to the turbocharger. Close the joint to the intermediate pipe and tighten the bolt securing the catalytic converter to the bracket.


8. Fit the air pipe and the hose between the turbocharger and charge air cooler. Lower the car.

9. Make sure that the radiator drain plug is tightened. Fill up with coolant and check the system for leaks.

10. Check the oil level and grade of oil.

11. Check the basic charging pressure, see and adjust as necessary.

12. Affix a seal to the push rod.