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Turbocharger, 4WD

Turbocharger, 4WD

To remove

Warning

The turbocharger can be hot and great care must be observed.


Warning

The cooling system is under pressure. Hot coolant and steam can escape.

- Open the cap slowly to release the pressure.

- Carelessness can cause eye and burn injuries



1. Remove the battery cover and the engine cover.

2. Take the cap (A) off the expansion tank to release any pressure.


3. Remove the battery cable.

4. Raise the car.

5. Undo the right-hand side of the spoiler shield.

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.


7. Remove the front nuts (A) of the rear catalytic converter and move aside. Fix in position with 83 95 212 Strap .


8. RHD: Remove Alternator, B284, 4WD, (RHD) .

9. LHD: Remove the right wing liner (A).


10. LHD: Relieve the load on the belt tensioner and unhook the belt. Use a ½" puller (B).


11. LHD: Disconnect the electrical connections (A) of the alternator.


12. LHD: Remove the alternator retaining bolts (B). Move the engine to the left slightly if necessary. Move the alternator rearward.

13. Unplug the oil level sensor connector (A) and remove the cable fixing (B).


14. Remove the bracket (C) from the front catalytic converter and oil sump.

15. Lower the car.

16. Remove the Fan cowling .

17. Detach the hoses (A) from the expansion tank.


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.

19. Remove the upper heat shield from the turbocharger (A) and catalytic converter (B).


20. Remove the turbocharger coolant return pipe (C).


21. Unplug the connector of the upper oxygen sensor (A) and move up the cable (B).


22. Carefully raise the heat shield slightly. Use 83 96 350 Removal socket, oxygen sensor when removing the oxygen sensor (C).

23. Remove the nuts (A). Lubricate the studs and nuts with rust removal oil.


24. Remove the catalytic converter from the bracket (B) and move it aside.

Note

Lubricate the studs and nuts with rust removal oil and carefully loosen.


25. Detach the inlet pipe (A) of the secondary air injection pump from the pump.


26. Detach the outlet pipe (B) of the secondary air injection pump from the pump.

27. Unplug the connector (C) of the secondary air pressure sensor (760).

28. Remove the pipe (D).

29. Unplug the intake air sensor connector (688) (A).


30. Detach the upper turbocharger delivery pipe (B).

31. Remove the screw (A) holding the dipstick tube.


32. Remove the heat shield (B) of the front exhaust manifold.

Note

Lubricate the studs and nuts with rust removal oil and carefully loosen.


33. Detach the intermediate exhaust pipe (A) from the turbocharger and the front exhaust manifold.


34. Detach the vacuum hoses and crankcase ventilation pipe from the turbocharger (A).


35. Detach the lower turbocharger delivery hose (B) from the turbocharger.

36. Detach the oil delivery pipe (A) from the engine.


37. Remove the oil return pipe (A) from the turbocharger.


38. Remove the oil delivery pipe's banjo screws (B) from the turbocharger.

39. Remove the coolant pipe's banjo screw (C) from the turbocharger.

40. Remove the nuts (D) of the rear intermediate exhaust pipe.

41. Remove the bolt (E) securing the turbocharger to the bracket using an impact socket and long puller. 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 (E) securing the turbocharger to the bracket.

Tightening torque: 65 Nm (48 lbf ft)

Important

The conical side of the nut should face the centre exhaust pipe.


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.

Note

Engine with aluminium washers: First fit washers part no. 551 700 02 on the banjo nipple where the tabbed gasket section is turned towards the turbo. Fit the banjo screw by screwing it through the gasket and then into the turbo.


Tightening torque 30 Nm (22 lbf ft)

5. Fit the oil delivery pipe's banjo screws (B) to the turbocharger using new gaskets.

Note

Engines with aluminium washers: first fit washers part no. 551 700 00 on the banjo nipple where the tabbed gasket section is turned towards the turbo. Fit the banjo screw by screwing it through the gasket and then into the turbo.


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)

7. Attach the oil delivery pipe (A) to the engine using new gaskets.


Note

Engine with aluminium washers: First fit washers part no. 551 700 00 on the banjo nipple where the tabbed gasket section is turned towards the engine. Fit the banjo screw by screwing it through the gasket and then into the engine.


Tightening torque 30 Nm (22 lbf ft)

Important

To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressure, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 93 160 907 Motip Dupli cleaning agent to wipe clean inside the ends of the hoses. Clean the connecting pieces as well. If hose clips are rusty or damaged, they must be replaced so the correct clamping force is maintained.


8. Attach the lower turbocharger delivery hose (B) to the turbocharger.


9. Attach the vacuum hoses and crankcase ventilation pipes to the turbocharger (A).

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 .

Important

The conical side of the nut should face the centre exhaust pipe.



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)

Important

The surfaces should align with one another when the nuts are fitted. Check using a feeler gauge. If the surfaces are not flat or the pipe is deformed, the centre exhaust pipe and/or exhaust manifold must be replaced.


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).


15. Plug in the intake air sensor connector (688) (A).

16. Fit the pipe (D).


17. Plug in the connector (C) of the secondary air pressure sensor (760).

18. Attach the secondary air injection pump's outlet pipe (B) to the pump.

19. Attach the secondary air injection pump's inlet pipe (A) to the pump.

Important

When fitting the front catalytic converter to the turbocharger, tighten the nuts in a crosswise pattern to avoid tightening the flange crooked.


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).

22. Fit the turbocharger's lower heat shield.

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.

25. Secure the cable (B) and plug in the connector (A).

26. Fit the turbocharger coolant pipe (C).


Tightening torque, banjo screw: 30 Nm (22 lbf ft).

Note

Engine with aluminium washers : First fit washers part no. 551 700 02 on the banjo nipple where the tabbed gasket section is turned towards the turbo. Fit the banjo screw by screwing it through the gasket and then into the turbo.


27. Fit the upper heat shield to the catalytic converter (B) and turbocharger (A).


28. Attach the lower hose (C) of the coolant reservoir and plug in the level sensor connector (B).


29. Fit the coolant reservoir in the mounting.

30. Attach the breather hoses (A) to the coolant reservoir.

31. Fit Fan cowling .

32. Raise the car.

33. Fit the bracket (C) to the front catalytic converter and oil sump.


34. Plug in the oil level sensor connector (A) and attach the cable fixing (B).

35. RHD: Remove Alternator, B284, 4WD, (RHD) .

36. LHD: Fit the alternator retaining bolts (B).


37. LHD: Connect the electrical connections (A) of the alternator.

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).


40. Fit the rear catalytic converter (A) using a new gasket.

Tightening torque 25 Nm (18 lbf ft)


41. Lower the car.

42. Carry out Cooling system pressure testing and Bleeding and charging the cooling system .

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

44. Connect the battery cable.

45. Fit the battery cover and the engine cover.

46. Remove the wing covers and restore car electrical functions, see After disconnecting the battery .

47. Start the engine and check for any exhaust, oil and coolant leakage.