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Turbo, A20NFT/LHU

Turbo, A20NFT/LHU



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. Slacken the turbo pipe (A) and move to one side.


2. Remove the heat shield (B).

3. Remove the connectors (H) to the oxygen sensors (D).

4. Remove the oxygen sensors (D).

5. Remove the nuts (C) between the turbo and the catalytic converter.

Important

When removing the nuts of the catalytic converter, it is important to hold the removal tool vertically against the flange. The stud and nut can easily be broken off if they are subjected to a skew loading. Use 82 92 484 Removal tool, door hinge.


6. Remove the oil delivery pipe's upper banjo bolt (K).

7. Remove the intake hose (R) between the mass air flow meter and the turbo.

8. Remove the vacuum hose (S) to the bypass valve.

9. Remove the connector (P) to the solenoid valve wastegate.

10. Remove the crankcase ventilation (J) between the camshaft cover and the turbo.

11. Unfasten the lid of the expansion tank (T).

12. Raise the car.

13. Remove the exhaust pipe (E) from the catalytic converter (G).

14. Remove the lower bracket (F) of the catalytic converter (G).

15. Remove the catalytic converter (G) from the car

16. Remove the Spoiler shield, front.

17. Drain coolant from the radiator's drain cock, see Draining, cooling system .

18. Lower the car.

19. Remove the coolant pipe's upper banjo bolt (U) from the turbo.

20. Undo the coolant pipe bracket (I).

21. Raise the car.

22. Remove the stabiliser stay (M) between the turbo (L) and the engine block.


23. Remove the coolant return pipe and its banjo bolts (N) from the turbo and thermostat housing.

Important

If the flexible part of the return oil pipe is bent, the resulting restriction may become permanent and cause damage to the turbocharger.


24. Undo the oil return pipe (O) from the turbo

25. Remove the turbocharger (L).


To fit


1. Position the turbocharger in the car with a new gasket and connect the oil return pipe (O) to the turbo.

2. Lubricate the studs for the turbo and exhaust manifold with 90 513 210 Universal paste .

3. Fit the turbocharger (L).

Tightening torque 30 Nm (22 lbf ft)


4. Fit the oil return pipe (O) to turbo.

Tightening torque 10 Nm (7 lbf ft)

5. Fit the coolant pipe and its banjo bolts (N) with new gaskets to the turbo (L) and the thermostat housing.

Tightening torque 45 Nm (33 lbf ft).

6. Fit the stay (M) between the turbo (L) and the engine block.

Tightening torque, nut: 50 Nm (37 lbf ft)

Tightening torque, screw: 58 Nm (43 lbf ft)


7. Position the catalytic converter (G).

8. Fit the catalytic converter's (G) lower bracket (F), insert without tightening.

9. Fit the exhaust pipe (E) to the catalytic converter (G).

Tightening torque 35 Nm (26 lbf ft)

10. Lower the car.

11. Connect the connector (P) to the solenoid valve wastegate.

12. Fit the coolant pipe's upper banjo bolt (U) with a new gasket to the turbo.

Tightening torque 45 Nm (33 lbf ft).

13. Fit the coolant pipe bracket (I).

14. Fit the vacuum hose (S) to the bypass valve.

15. Fit the nuts (C) between the turbo (L) and the catalytic converter (G).

Tightening torque 50 Nm (37 lbf ft)

16. Fill with plenty of engine oil in the hole for the oil delivery connection (K) on the turbo while turning the turbine wheel

17. Fit the oil delivery pipe's upper banjo bolt (K) with a new gasket.

Tightening torque 45 Nm (33 lbf ft).

18. Raise the car.

19. Fit the Spoiler shield, front.

20. Fit the lower bracket (F) of the catalytic converter (G), then tighten it.

Tightening torque: 58 Nm (43 lbf ft)

21. Lower the car.

22. Lightly lubricate the threads for the oxygen sensors (D) with 90 513 210 Universal paste .

23. Fit the oxygen sensors (D).

Tightening torque 42 Nm (31 lbf ft)

Important

Make sure cables to the oxygen sensor are not twisted or damaged.


24. Fit the oxygen sensors' (D) connectors (H).

25. Fit the crankcase ventilation (J) between the camshaft cover and the turbo (L).

26. Lift up the oxygen sensor cables.

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.


27. Fit the intake hose (R).

28. Fit the heat shield (B) over the turbocharger.

Tightening torque 10 Nm (7 lbf ft)

29. Fit the turbo pipe (A).

Tightening torque 22 Nm (16 lbf ft)

30. Fill with coolant.

31. Check the oil and coolant level and top up as necessary.