Right Turbocharger, Removing and Installing

Right turbocharger, removing and installing

Special tools and equipment
^ Drip tray

Removing
- Remove engine

Note: All cable ties which are released or cut open when removing must be installed in same position when installing.

- Place a drip tray underneath.
- Drain engine oil.
- Place engine/transmission assembly on work bench or engine/transmission stand. Support/secure engine and transmission with pieces of squared timber.

WARNING: Engine/transmission assembly must be securely supported to avoid risk of accident

- Unplug connectors for right oxygen sensors before and after catalytic converter.
- Move wiring clear.





- Unbolt front right exhaust pipe from turbocharger (arrows).





- Unscrew bolt (arrow) and detach oil return pipe from upper section of sump.





- Disconnect vacuum hose -2-.
- Remove bolt -3-.
- Release hose clamp -4-.
- Unscrew temperature sensor of exhaust gas temperature sender -1-.
- Unscrew nuts -5-.





- Unthread bolt (arrow) and remove pressure line from turbocharger.

Note: Depicted in illustration with exhaust manifold removed.





- Remove nuts -1-to -12-.
- Remove heat shield over differential cover of transmission.
- Pull turbocharger slightly downward and remove exhaust manifold.





- Remove banjo fittings -1- to -3- and remove turbocharger.

Note: Disregard -item 4-.

Installing
Install in reverse sequence; note following points:

Note:
^ Always replace gaskets, seals and self-locking nuts.
^ Fill turbocharger with engine oil at connection of oil supply pipe.
^ Connection of temperature sensor for exhaust gas temperature sender must face downward when installing. Guide line upward in a loop.
^ All cable ties which are opened or cut open on removal must be replaced in same position when installing.
^ Remove any traces of oil or grease on hose connections and hoses for charge air system before installing. Do not apply lubricant.
^ Secure all hose connections with correct hose clamps (same as original equipment) See parts catalog.

- Initially screw on nuts securing turbocharger to exhaust manifold hand-tight.
- Initially screw on nuts securing front exhaust pipe to turbocharger hand-tight.





- Check distance between front exhaust pipe and transmission housing at position marked with arrows.
^ Distance a = 9.0 to 9.5 mm

- Tighten nuts securing exhaust manifold/turbocharger and turbocharger/front exhaust pipe.
- Put in engine oil.
- Install engine

Note: After installing turbocharger, run engine for approximately 1 minute at idling speed; do not rev. engine immediately. This ensures turbocharger is properly lubricated.





Tightening torques