Turbocharger: Service and Repair

Remove





- the heat deflector plate over the exhaust manifold

Disconnect the components from the turbocharger





Disconnect upper charge air pipe with lower rubber hose, from the Turbocharger (TC) and place it to one side.
Remove fresh air intake.
Remove inner heat deflector plate.
Slacken off the Turbocharger (TC) upper coolant return pipe, clamp the coolant hose with lock grip pliers and place the pipe/hose to one side.
Slacken off oil inlet nipple.
Raise the car

Remove





- the clamp between pipes
- oil return line
- exhaust pipe bracket screw
- exhaust pipe-Turbocharger (TC) nut
- exhaust manifold-Turbocharger (TC) nuts

Apply lock grip pliers to the coolant inlet hose.
Lower the car.

Remove Turbocharger (TC)





Remove exhaust pipe-Turbocharger (TC) nuts.
Remove coolant inlet pipe.
Remove the nuts, Turbocharger (TC)-exhaust manifold.

Disconnect the hoses for:





- boost pressure (red)
- by-pass valve (white)
- pressure regulator (yellow)

Remove
- Turbocharger (TC)
- old studs from exhaust manifold.

Note! Studs should always be secured with strong thread sealant, P/N 1161076-5, when installed.

Install





- new studs (if any are missing) tighten to 20 Nm
- Turbocharger (TC)
- hoses according to marking
- both upper exhaust manifold nuts, and tighten them slightly

raise the car

Install





- exhaust manifold lower nuts, tighten to 25 Nm.

Tighten Turbocharger (TC)





Tighten upper exhaust manifold bolts to 25 Nm.
Tighten exhaust manifold to Turbocharger (TC), tighten all nuts to 30 Nm at the same time checking that the planes are parallel.
Raise the car

Install lower oil pipe





Install oil pipe (lubricate O-ring).
Install exhaust pipe bracket screw.
Lower the car.

Install





- oil inlet pipe
- Inlet and outlet coolant pipes (remove lock grip pliers)
- fresh air intake hose
- inner heat deflector plate
- upper charge air pipe
- outer heat deflector plate

Note! Install new copper washers for the coolant pipe and for the upper oil pipe.

Raise the car

Install clamp between pipes





Remove lock grip pliers from coolant return hose.
Lower the car.

Test function
Check boost pressure.
Check oil and coolant levels.
Check oil and coolant levels.

Hint: Diagnostic trouble code (DTC) 3-5-2 can occur after turbocharger replacement, if so reset