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Turbo unit, 4-cyl

Turbo unit, 4-cyl

Warning

The exhaust pipe from the turbocharger can be extremely hot. Proceed with caution.


To remove

If the turbo is to be replaced, carry out Procedure before turbo replacement, 4-cyl .


1. Put protection on the wings.

2. Remove the battery cover and disconnect the negative battery cable.


3. Remove the upper engine cover.

4. Remove the intake manifold from the mass air flow sensor to the turbocharger and camshaft cover.


5. Remove the charge air pipe from the turbo and camshaft cover. Plug the charge air pipe and turbo inlet.

6. Detach the cable mounting from the camshaft cover and unplug the connectors from the glow plugs. Move them aside.


7. Remove the heat shields over the turbo and exhaust manifold. Undo one of the bolts of the lifting eye for access.


8. Remove the top bolt on the exhaust manifold support and loosen the bottom one so that the support can be rotated out of the way.


9. Remove the turbo's oil delivery pipe.

Important

Work carefully so that the bellows is not bent or cracked.


10. Detach the turbo's oil delivery pipe from the engine block.


11. Detach the vacuum hose from the control valve diaphragm unit.

12. Detach the exhaust pipe from the turbocharger.

13. Remove the exhaust manifold and lift out the turbo with exhaust manifold.

14. Detach the turbo from the exhaust manifold.

15. When replacing the turbo: transfer the oil delivery pipe to the new turbo. Use new seals.


To fit


1. Clean the sealing surfaces. Apply 90 513 210 Universal paste to the sealing surfaces and studs, and fit the turbo to the exhaust manifold.


Tightening torque: 30 Nm (22 lbf ft).

2. Clean the sealing surfaces. Apply 90 513 210 Universal paste to the studs and fit the exhaust manifold onto the cylinder head with a new gasket and new nuts.

Tightening torque 22 Nm (16 lbf ft)

3. Connect the vacuum hose to the regulating valve diaphragm box.

4. Connect the turbo's oil delivery pipe to the engine block.

Tightening torque: 30 Nm (22 lbf ft).

5. Apply 90 513 210 Universal paste to the turbo studs.

6. Attach the exhaust pipe to the turbocharger.

7. Fill the turbo's delivery oil channel with engine oil. Rotate the turbo's shaft a few times and top up as necessary.

Important

It is very important that the turbocharger contains oil when the engine is started.


8. Tighten the oil delivery pipe connection to the turbo using new sealing washers.

Tightening torque: 20 Nm (15 lbf ft)

9. Move back the exhaust manifold stay and tighten the bolts.

10. Refit the heat shield over the exhaust manifold and turbo. Tighten the bolt on the lifting eye.


11. Plug in the glow plugs and fit the cable mounting to the camshaft cover.


12. Fit the charge air pipe to the turbo and camshaft cover.


13. Fit the intake manifold from the mass air flow sensor to the turbo and the hose for the crankcase ventilation.

Tightening torque, mass air flow sensor: 3.5 Nm (2.5 lbf ft)

14. Refit the upper engine cover.


15. Connect the negative battery cable and fit the battery cover.

16. Adjust the clock, SID and ACC.

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

18. Start the engine and check for leaks.