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Turbo unit, V6

Turbo unit, V6

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, V6 .


1. Raise the car.

2. Remove the lower engine cover.


3. Remove the catalytic converter from the front exhaust pipe.


4. Remove the bolts from the catalytic converter bracket on the gearbox.

5. Lower the car to the floor.

6. Remove the intake manifold from the mass air flow sensor to the turbocharger.


7. Remove the upper engine cover.

8. Detach the turbo pressure hose from the intake manifold.

9. Remove the turbocharger heat shield.

10. Remove the upper intake manifold.


11. Remove the battery cover.


12. Remove the battery terminals and lift out the battery.

13. Remove the holder for the main fuses.

14. Remove the battery tray.

15. Remove the catalytic converter from the turbocharger.


16. Detach the vacuum hose and connector from the diaphragm unit.

17. Detach the turbocharger delivery pipe's anchorage to the gearbox from the turbocharger.

18. Remove the vacuum clock mounting from the turbo.


19. Loosen the cap of the coolant expansion tank and release any overpressure. Refit the cap.

20. Detach the water pipes from the turbo.

21. Remove the turbocharger oil pipe from the engine block.

22. Remove the banjo connection of the turbocharger oil pipe from the engine block.

23. Remove the turbo.


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. Apply Molykote 1000, part no. 30 20 971, to the studs. Fit new seals for the oil pipes and fit the turbo using new seals. Tighten the turbo.

Tightening torque: 21 Nm (16 lbf ft)


2. Tighten the banjo connection to the engine block.

Tightening torque: 20 Nm (15 lbf ft)

3. Tighten the return oil pipe connected to the engine block.

Tightening torque: 30 Nm (22 lbf ft).

4. Fit the water pipes to the turbocharger using new seals.

Tightening torque: 25 Nm (18 lbf ft).

5. Fit the vacuum clock to the turbo. Connect the vacuum hose and connector.

6. Fit the turbo delivery pipe to the turbo and the anchorage in the gearbox.


7. Fit the catalytic converter to the turbo. Apply Molykote 1000, part no. 30 20 971, to the studs. Do not tighten the nuts.

8. Fit the battery tray.


9. Fit the fuse board.

10. Fit the battery.

11. Fit the battery terminals and the battery cover.

12. Fit the mounting between the intake manifold and the turbo.

Tightening torque: 21 Nm (16 lbf ft)

13. Raise the car.

14. Fit the catalytic converter mounting to the gearbox.


15. Fit the catalytic converter to the front pipe.

Tightening torque: 24 Nm (18 lbf ft)

16. Fit the lower engine cover.


17. Lower the car to the floor.

18. Tighten the catalytic converter nuts on the turbocharger.

Tightening torque: 24 Nm (18 lbf ft)

19. Fit the upper intake manifold using new gaskets.

Tightening torque: 22 Nm (16 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.


20. Connect the turbocharger delivery hose to the upper intake manifold.


21. Fit the turbocharger heat shield.

22. Fit the upper engine cover.

23. Fit the intake manifold to the mass air flow sensor and turbocharger.

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

24. Fill with coolant as necessary. See Coolant .

25. Adjust the clock.