Turbocharger, 4WD
Turbocharger, 4WD |
To remove |
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1. |
Remove the battery cover and the engine cover.
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2. |
Take the cap (A) off the expansion tank to release any pressure.
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3. |
Remove the battery cable.
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4. |
Raise the car.
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5. |
Undo the right-hand side of the spoiler shield.
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6. |
Place a suitable receptacle under the radiator. Connect a hose (A) to the radiator (B) and drain the coolant. Close the cock and refit the spoiler shield.
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7. |
Remove the front nuts (A) of the rear catalytic converter and move aside. Fix in position with
83 95 212 Strap
.
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8. |
RHD:
Remove
Alternator, B284, 4WD, (RHD)
.
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9. |
LHD:
Remove the right wing liner (A).
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10. |
LHD:
Relieve the load on the belt tensioner and unhook the belt. Use a ½" puller (B).
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11. |
LHD:
Disconnect the electrical connections (A) of the alternator.
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12. |
LHD:
Remove the alternator retaining bolts (B). Move the engine to the left slightly if necessary. Move the alternator rearward.
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13. |
Unplug the oil level sensor connector (A) and remove the cable fixing (B).
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14. |
Remove the bracket (C) from the front catalytic converter and oil sump.
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15. |
Lower the car.
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16. |
Remove the
Fan cowling
.
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17. |
Detach the hoses (A) from the expansion tank.
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18. |
Move up the tank, unplug the level sensor connector (B) and remove the quick coupling of the coolant hose (C). Lift away the coolant reservoir.
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19. |
Remove the upper heat shield from the turbocharger (A) and catalytic converter (B).
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20. |
Remove the turbocharger coolant return pipe (C).
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21. |
Unplug the connector of the upper oxygen sensor (A) and move up the cable (B).
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22. |
Carefully raise the heat shield slightly. Use
83 96 350 Removal socket, oxygen sensor
when removing the oxygen sensor (C).
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23. |
Remove the nuts (A). Lubricate the studs and nuts with rust removal oil.
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24. |
Remove the catalytic converter from the bracket (B) and move it aside.
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25. |
Detach the inlet pipe (A) of the secondary air injection pump from the pump.
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26. |
Detach the outlet pipe (B) of the secondary air injection pump from the pump.
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27. |
Unplug the connector (C) of the secondary air pressure sensor (760).
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28. |
Remove the pipe (D).
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29. |
Unplug the intake air sensor connector (688) (A).
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30. |
Detach the upper turbocharger delivery pipe (B).
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31. |
Remove the screw (A) holding the dipstick tube.
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32. |
Remove the heat shield (B) of the front exhaust manifold.
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33. |
Detach the intermediate exhaust pipe (A) from the turbocharger and the front exhaust manifold.
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34. |
Detach the vacuum hoses and crankcase ventilation pipe from the turbocharger (A).
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35. |
Detach the lower turbocharger delivery hose (B) from the turbocharger.
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36. |
Detach the oil delivery pipe (A) from the engine.
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37. |
Remove the oil return pipe (A) from the turbocharger.
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38. |
Remove the oil delivery pipe's banjo screws (B) from the turbocharger.
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39. |
Remove the coolant pipe's banjo screw (C) from the turbocharger.
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40. |
Remove the nuts (D) of the rear intermediate exhaust pipe.
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41. |
Remove the bolt (E) securing the turbocharger to the bracket using an impact socket and long puller. Remove the turbocharger.
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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. |
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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. |
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1. |
Position the turbocharger.
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2. |
Fit the bolt (E) securing the turbocharger to the bracket.
Tightening torque: 65 Nm (48 lbf ft)
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3. |
Fit the nuts (D) of the rear intermediate exhaust pipe. Tighten alternatingly.
Tightening torque 30 Nm (22 lbf ft) |
4. |
Fit the coolant pipe's banjo screw (C) to the turbocharger. Use new gaskets.
Tightening torque 30 Nm (22 lbf ft) |
5. |
Fit the oil delivery pipe's banjo screws (B) to the turbocharger using new gaskets.
Tightening torque 30 Nm (22 lbf ft) |
6. |
Fit the oil return pipe (A) to the turbocharger. Use new gaskets.
Tightening torque: 14 Nm (10 lbf ft) |
8. |
Attach the lower turbocharger delivery hose (B) to the turbocharger.
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9. |
Attach the vacuum hoses and crankcase ventilation pipes to the turbocharger (A).
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10. |
Attach the intermediate exhaust pipe (A) to the front exhaust manifold and the turbocharger. Use a new gasket and coat the studs with
90 513 210 Universal paste
.
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11. |
Tighten the nuts as illustrated - first on the exhaust manifold and then on the turbocharger.
Tightening order (B1, B2, B3 and B4) alternatingly on the turbocharger. Tightening torque 30 Nm (22 lbf ft)
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12. |
Fit the front exhaust manifold heat shield (B).
Tightening torque 10 Nm (7 lbf ft) |
13. |
Fit the screw (A) holding the dipstick tube.
Tightening torque 10 Nm (7 lbf ft) |
14. |
Fit the upper turbocharger delivery pipe (B).
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15. |
Plug in the intake air sensor connector (688) (A).
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16. |
Fit the pipe (D).
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17. |
Plug in the connector (C) of the secondary air pressure sensor (760).
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18. |
Attach the secondary air injection pump's outlet pipe (B) to the pump.
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19. |
Attach the secondary air injection pump's inlet pipe (A) to the pump.
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20. |
Fit the catalytic converter nuts (A) to the turbocharger. Coat the studs with
90 513 210 Universal paste
.
Tightening torque 25 Nm (18 lbf ft) |
21. |
Fit the catalytic converter to the bracket (B).
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22. |
Fit the turbocharger's lower heat shield.
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23. |
Lightly coat the threads of the front oxygen sensor with
90 513 210 Universal paste
and fit the oxygen sensor (C) using
83 96 350 Removal socket, oxygen sensor
.
Tightening torque 45 Nm (33 lbf ft). |
24. |
Carefully press down the heat shield.
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25. |
Secure the cable (B) and plug in the connector (A).
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26. |
Fit the turbocharger coolant pipe (C).
Tightening torque, banjo screw: 30 Nm (22 lbf ft).
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27. |
Fit the upper heat shield to the catalytic converter (B) and turbocharger (A).
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28. |
Attach the lower hose (C) of the coolant reservoir and plug in the level sensor connector (B).
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29. |
Fit the coolant reservoir in the mounting.
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30. |
Attach the breather hoses (A) to the coolant reservoir.
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31. |
Fit
Fan cowling
.
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32. |
Raise the car.
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33. |
Fit the bracket (C) to the front catalytic converter and oil sump.
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34. |
Plug in the oil level sensor connector (A) and attach the cable fixing (B).
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35. |
RHD:
Remove
Alternator, B284, 4WD, (RHD)
.
|
36. |
LHD:
Fit the alternator retaining bolts (B).
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37. |
LHD:
Connect the electrical connections (A) of the alternator.
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38. |
LHD:
Relieve the load on the belt tensioner and position the belt. Use a ½" puller (B).
|
39. |
LHD:
Fit the right wing liner (A).
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40. |
Fit the rear catalytic converter (A) using a new gasket.
Tightening torque 25 Nm (18 lbf ft) |
41. |
Lower the car.
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42. |
Carry out
Cooling system pressure testing
and
Bleeding and charging the cooling system
.
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43. |
Check the oil level and top up as necessary.
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44. |
Connect the battery cable.
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45. |
Fit the battery cover and the engine cover.
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46. |
Remove the wing covers and restore car electrical functions, see
After disconnecting the battery
.
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47. |
Start the engine and check for any exhaust, oil and coolant leakage.
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