Turbocharger: Service and Repair
Removing and Installing Turbocharger
Removing Turbocharger
Preliminary work: Disassemble the accessories of the rear spoiler (includes rear end, lower central heat shield and bumper) See Removing and installing rear spoiler.
CAUTION:
Danger of burns. Parts of the exhaust system can be extremely hot. Do not begin work until the exhaust system has cooled down.
1. Remove charge air cooler. To do this, disconnect both hose connections on the charge air cooler.
2. Then unscrew the two fastening screws and the hexagon nuts on the air charge cooler.
3. Unscrew the rear hexagon nut and the fastening screw.
4. Undo the two fastening nuts on the heat shield.
5. Take the charge air cooler out of the vehicle.
6. Remove heat shield. Unscrew the heat shield covering the catalytic converter and the turbocharger. Undo the two fastening nuts on the vehicle for this purpose.
WARNING:
Danger of fire. The heat shield should not be bent or deformed. Bent or deformed heat shields must be replaced.
7. Undo oil pipe and turbocharger support. Open and unscrew the upper oil pipe of the turbocharger at the uppermost screw connection. Make sure to counter with an open ring wrench when doing this. Then open the support of the turbocharger.
8. Pull off vacuum line. Pull off the vacuum line on the control box. Push a small screwdriver between connection nipple and vacuum hose. Widen vacuum hose a little and spray in silicone spray at the same time. Remove vacuum hose with angled pliers.
CAUTION:
Damage to the control box. Never lever off the hose with a screwdriver.
9. Screw off oil pipes. Open the two oil pipes on the oil container. Collect draining oil.
10. Undo pressure pipe from turbocharger. Undo the hose clamp and remove the pressure hose from the exhaust turbocharger for this purpose.
11. Unscrew the four fastening nuts on the turbocharger flange to the catalytic converter.
12. Unscrew exhaust manifold. Unscrew the nine fastening screws for this purpose. Remove turbocharger with exhaust manifold.
13. Open separation point between turbocharger and exhaust manifold.
Installing Turbocharger
1. Fit turbocharger. Insert a new seal between the turbocharger and the exhaust manifold and tighten the three fastening screws to 30 Nm (22 ftlb.).
2. Tighten exhaust manifold on the cylinder head. Position exhaust manifold with new seals (cylinder head and on the catalytic converter) on the cylinder head and insert in the exhaust catalytic converter at the same time. Position the nine fastening screws on the cylinder head by hand and tighten in two stages. First stage 25 Nm (18 ftlb.). Second stage 33 Nm (24 ftlb.).
Tightening occurs in two stages (first 25 Nm (18 ftlb.), then 33 Nm (24 ftlb.)) according to the sequence shown.
3. Replace the four fastening nuts to the exhaust catalytic converter and tighten to 30 Nm (22 ftlb.).
4. Tighten the two oil pipes to 30 Nm (22 ftlb.) each.
5. Screw on the turbocharger support. Do not forget the washer beneath the new hexagon nut when doing this. Tighten the hexagon nut to 23 Nm (17 ftlb.). Then position the hexagon nut of the vent line by hand and tighten to 20 Nm (15 ftlb.).
6. Install heat shield. Move heat shield into installation position again and tighten the two sheetmetal nuts.
7. Push the pressure pipe back onto the turbocharger and tighten the hose clamp.
8. Install charge air cooler. Insert the charge air cooler in the studs on the body. Tighten the rear fastening nut and the two fastening screws to 23 Nm (17 ftlb.).
9. Tighten the front fastening nut and the fastening screw to 23 Nm (17 ftlb.).
10. Tighten the two sheetmetal nuts on the heat shield.
11. Reconnect the two hose connections. Make sure that the clips are properly inserted when doing this. Press in the hose support until it is heard to engage.
12. Carry out oil level and tightness test.
NOTE: Conclude by carrying out oil level and tightness test.
Tightening torques