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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 and charge air pipe (2 bolts under the wiring harness). Plug the hoses.


3. Remove the mounting on the camshaft cover

4. Disconnect the glow plugs.

5. Remove the crankcase ventilation hose and the induction hose from the turbocharger.

6. Remove the heat shields from the turbocharger, exhaust manifold and starter motor. Slacken one of the lifting eye bolts for clearance. The lower heat shield bracket for the starter motor only needs to be loosened.


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

8. Remove the nuts securing the front exhaust pipe to the turbocharger.

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


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 slightly loosen the lower bolt so that the support can be moved aside. Lower the car.

15. Detach the vacuum hose from the wastegate diaphragm unit. Remove the exhaust manifold and lift out the turbo unit with exhaust manifold.

16. Remove the turbocharger from the exhaust manifold.

17. When replacing the turbo unit: transfer the oil pipes to the new turbo unit. Use new seals.


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. Reposition the exhaust manifold and tighten the bolts.

Tightening torque 25 Nm (18.5 lbf ft).

6. Connect the turbocharger oil return pipe to the cylinder block.

Tightening torque 30 Nm (22 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 exhaust pipe to the intermediate pipe.

Tightening torque 20 Nm (15 lbf ft).

11. Fit the lower cover and lower the car.


12. Tighten the nuts between the turbocharger and the front exhaust pipe.

Tightening torque 20 Nm (15 lbf ft).


13. 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.


14. Tighten the oil delivery pipe connection to the turbocharger with new sealing washers.

Tightening torque 20 Nm (15 lbf ft).

15. Fit the wiring harness duct to the engine.

16. Refit the heat shields over the exhaust manifold, turbocharger and starter motor. Tighten the bolt on the lifting eye.

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.


17. Connect the induction hose and the crankcase ventilation hose to the turbocharger.


18. Connect the glow plugs.

19. Fit the bracket on the camshaft cover.

20. Fit the charge air pipe.

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.