Turbo
Turbo |
To remove |
|
|
1. |
Remove the battery cover and the engine cover.
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2. |
Remove the battery cable.
|
3. |
Take the cap off the expansion tank to release any pressure.
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4. |
Raise the car.
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5. |
Undo the right-hand side of the spoiler shield.
|
6. |
Place a suitable receptacle under the radiator. Connect a hose to the radiator and drain the coolant. Close the cock and refit the spoiler shield.
|
7. |
CV
: Remove
Chassis reinforcement, front subframe, CV
.
|
8. |
Remove the front nuts of the rear catalytic converter and move aside. Fix in position with
83 95 212 Strap
.
|
9. |
Remove the mounting from the front catalytic converter and oil sump using
32 025 061 Crow foot spanner
.
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10. |
Lower the car.
|
11. |
Remove the battery.
|
12. |
Remove
Battery cover, bottom, B284
.
|
13. |
Detach the breather hoses from the coolant reservoir.
|
14. |
Detach the breather pipe from the turbocharger and heat shield.
|
15. |
Detach and raise the expansion tank slightly.
|
16. |
Detach the lower hose of the coolant reservoir, unplug the level sensor connector and lift away the coolant reservoir.
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17. |
Remove the upper heat shield from the turbocharger.
|
18. |
Remove the bolt of the ventilation pipe mounting.
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19. |
Unplug the upper oxygen sensor connector and remove the cable fixings. Move the cable up.
|
20. |
Carefully raise the heat shield slightly. Use
83 96 350 Removal socket, oxygen sensor
when the oxygen sensor is removed.
|
21. |
Remove the turbocharger's lower heat shield.
|
22. |
Remove the bolt of the catalytic converter mounting.
|
23. |
Remove the catalytic converter nuts to the turbocharger.
|
24. |
Remove
Upper radiator member, B284E
.
|
25. |
Unplug the mass air flow sensor connector. Detach the secondary air pipe, the delivery hose from the turbocharger intake manifold and the crankcase ventilation pipes.
|
26. |
Detach the turbocharger intake manifold from the air cleaner casing cover and the turbocharger.
|
27. |
Remove the bypass valve and unplug the connector.
|
28. |
Remove the upper radiator mounting.
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29. |
Unplug the radiator fan connectors and detach the wiring harness from the fan cowling.
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30. |
Remove the bolts of the lower turbocharger delivery pipe and the fan cowling.
|
31. |
Press the radiator assembly forward and remove the fan cowling.
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32. |
Detach the intake manifold of the secondary air injection pump from the pump.
|
33. |
Detach the discharge pipe of the secondary air injection pump from the pump.
|
34. |
Unplug the intake air sensor connector (688).
|
35. |
Detach the upper turbocharger delivery pipe.
|
36. |
Remove the screw holding the dipstick tube.
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37. |
Remove the heat shield of the front exhaust manifold.
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38. |
Detach the intermediate exhaust pipe from the turbocharger and the front exhaust manifold.
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39. |
Detach the vacuum hoses and crankcase ventilation pipe from the turbocharger.
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40. |
Detach the lower turbocharger delivery hose from the turbocharger.
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41. |
Detach the oil delivery pipe from the engine.
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42. |
Remove the oil return pipe from the turbocharger.
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43. |
Remove the oil delivery pipe's banjo screws from the turbocharger.
|
44. |
Remove the coolant pipe's banjo screw from the turbocharger.
|
45. |
Remove the nuts of the rear intermediate exhaust pipe.
|
46. |
Remove the bolt holding the turbocharger to the bracket. Use an impact socket and a long puller.
|
47. |
Remove the turbocharger.
|
To fit |
Important | ||
It is essential that there is oil in the turbocharger bearing housing when the engine is started, especially after a new turbocharger has been fitted. |
||
Fill the turbocharger's oil inlet with oil from an oilcan. Rotate the compressor wheel by hand a number times to ensure that oil enters the bearings. |
||
1. |
Position the turbocharger.
|
2. |
Fit the bolt that holds the turbocharger to the bracket.
Tightening torque: 65 Nm (48 lbf ft) |
3. |
Fit the nuts of the rear intermediate exhaust pipe. Tighten alternatingly.
Tightening torque 30 Nm (22 lbf ft).
|
4. |
Fit the coolant pipe's banjo screw to the turbocharger. Use new gaskets.
Tightening torque 30 Nm (22 lbf ft). |
5. |
Fit the oil delivery pipe's banjo screws to the turbocharger using new gaskets.
Tightening torque 30 Nm (22 lbf ft). |
6. |
Attach the oil return pipe to the turbocharger using new gaskets.
Tightening torque: 14 Nm (10 lbf ft) |
8. |
Attach the lower turbocharger delivery hose to the turbocharger.
|
9. |
Attach the vacuum hoses and crankcase ventilation pipes to the turbocharger.
|
10. |
Attach the intermediate exhaust pipe to the front exhaust manifold and the turbocharger. Use a new gasket and coat the studs with
90 513 210 Universal paste
.
|
11. |
Tighten the nuts as illustrated - first on the exhaust manifold and then on the turbocharger. Tightening order 11a, 11b, 11c, and 11d alternatingly on the turbocharger.
Tightening torque 30 Nm (22 lbf ft)
|
12. |
Fit the heat shield of the front exhaust manifold.
Tightening torque 10 Nm (7 lbf ft) |
13. |
Fit the screw holding the dipstick tube.
Tightening torque: 10 Nm (7 lbf ft). |
14. |
Fit the upper turbocharger delivery pipe.
|
15. |
Plug in the intake air sensor connector (688).
|
16. |
Attach the discharge pipe of the secondary air injection pump.
|
17. |
Attach the secondary air injection pump's intake manifold to the pump.
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18. |
Press the radiator assembly forward and position the fan cowling.
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19. |
Fit the bolts of the lower turbocharger delivery pipe and the fan cowling.
|
20. |
Plug in the radiator fan connectors and attach the wiring harness to the fan cowling.
|
21. |
Fit the upper radiator mounting.
|
22. |
Fit the bypass valve and plug in the connector.
|
23. |
Attach the turbocharger intake manifold to the turbocharger and the air cleaner casing cover.
|
24. |
Plug in the mass air flow sensor connector. Attach the secondary air pipe, the delivery hose to the turbocharger intake manifold and the crankcase ventilation pipes.
|
25. |
Fit
Upper radiator member, B284E
.
|
26. |
Fit the catalytic converter nuts to the turbocharger. Coat the studs with
90 513 210 Universal paste
.
Tightening torque 25 Nm (18 lbf ft). |
27. |
Fit the bolt of the catalytic converter mounting.
|
28. |
Fit the turbocharger's lower heat shield.
|
29. |
Lightly coat the threads of the front oxygen sensor with
90 513 210 Universal paste
and fit the oxygen sensor using
83 96 350 Removal socket, oxygen sensor
.
Tightening torque 45 Nm (33 lbf ft). |
30. |
Carefully press down the heat shield.
|
31. |
Secure the cable and plug in the connector.
|
32. |
Fit the bolt of the ventilation pipe mounting.
|
33. |
Fit the upper heat shield to the turbocharger.
|
34. |
Attach the lower hose of the coolant reservoir and plug in the level sensor connector.
|
35. |
Fit the coolant reservoir in the mounting.
|
36. |
Attach the breather pipe to the turbocharger and heat shield. Use a new gasket.
Tightening torque, banjo screw: 30 Nm (22 lbf ft).
|
37. |
Attach the breather hoses to the coolant reservoir.
|
38. |
Fit
Battery cover, bottom, B284
.
|
39. |
Fit the battery.
|
40. |
Raise the car.
|
41. |
Fit the mounting on the front catalytic converter and oil sump.
|
42. |
Fit the rear catalytic converter using a new gasket.
Tightening torque 25 Nm (18 lbf ft). |
43. |
CV
: Fit
Chassis reinforcement, front subframe, CV
.
|
44. |
Lower the car.
|
45. |
Carry out
Cooling system pressure testing
and
Bleeding and charging the cooling system, B284
.
|
46. |
Check the oil level and top up as necessary.
|
47. |
Connect the battery cable.
|
48. |
Fit the battery cover and the engine cover.
|
49. |
Remove the wing covers and restore car electrical functions, see
After disconnecting the battery
.
|
50. |
Start the engine and check for any exhaust, oil and coolant leakage.
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