Turbocharger: Service and Repair

Turbocharger (TC)

Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.

Removing the turbocharger (TC)





Remove
- the cross stay between the suspension turrets
- the heat deflector plate over the turbocharger (TC)
- the charge air hose and the charge air pipe above the engine.
Remove the hose clamps for the turbocharger (TC) intake manifold at the air cleaner (ACL) and the turbocharger (TC). Pull off the pipe from the connections. Put the pipe to one side.

Install lock grip pliers on the rubber hose to the coolant inlet pipe for the turbocharger (TC).





Remove
- the pipe screws where the coolant pipes are connected to the turbocharger (TC).
Bend the outlet pipe upwards. Tie it into place
- the pipe screw where the oil pressure pipe connects to the turbocharger (TC)
- the upper nuts where the front exhaust pipe is connected to the turbocharger (TC)
- the upper nuts where the turbocharger (TC) is connected to the manifold.





Raise the car and remove
- the splash guard under the engine
- the clamp between the turbocharger (TC) oil pressure pipe and the oil return line
- the pipe screw where the oil pressure pipe connects to the cylinder block. Lift out the pipe
- the screws where the oil return line connects to the turbocharger (TC). Pull the pipe from the cylinder block. Check that the rubber sealing ring comes away with the pipe. Seal the opening in the cylinder block
- the lower nut where the front exhaust pipe is connected to the turbocharger (TC)
- the lower nuts where the turbocharger (TC) is connected to the manifold.





Lower the car
Remove the exhaust pipe from the turbocharger (TC). Hold the pipe to one side and tie it into place.
Lift off the turbocharger (TC). Mark up and remove the turbocharger (TC) hoses.
Place the turbocharger (TC) above the drive shaft and steering gear.
Raise the car.
Remove the turbocharger (TC).

Replacing the manifold and gasket





Remove
- heat deflector plate over the manifold
- the screws between the support bracket and the cylinder block
- the nuts and washers holding the manifold to the cylinder head.

Clean the gasket faces. Check that all studs are tightened.
Install new gaskets
Install the manifold. Use new nuts. Tighten to 25 Nm.

Checking the pressure regulator
When replacing the turbocharger, check the setting of the pressure regulator. See Wastegate valve, adjusting, B5254T2 Wastegate Valve, Adjusting.

Installing the turbocharger (TC)





Install
- the screws between the support bracket and the cylinder block
- heat deflector plate over the manifold





Raise the car
Position the turbocharger (TC) on the drive shaft and steering gear.
Lower the car
Lift up the turbocharger (TC). Install the turbocharger (TC) hoses using the marking made earlier.

Install
- the turbocharger (TC) on the manifold
- the upper nuts where the turbocharger (TC) is connected to the manifold. Do not tighten yet.
- the upper nuts where the front exhaust pipe is connected to the turbocharger (TC). Do not tighten yet.

Raise the car.
- the lower nuts where the turbocharger (TC) is connected to the manifold. Tighten to 25 Nm
- the lower nut where the front exhaust pipe is connected to the turbocharger (TC). Tighten to 30 Nm
- the oil pressure pipe to the connection at the cylinder block. Use a pipe screw and new seal washers.





Lower the car. Install
- the pipe screw for the oil pressure pipe to the connection at the turbocharger (TC). Use new seal washers. Tighten to 26 Nm.

Tighten the upper nuts where the turbocharger (TC) is connected to the manifold. Tighten to 25 Nm. Tighten the nuts where the front exhaust pipe connects to the turbocharger (TC). Tighten to 30 Nm
- the pipe screws for the coolant pipes. Use new seal washers. Tighten to 26 Nm
- the intake pipe between the air cleaner (ACL) and the turbocharger (TC).

Remove the lock grip pliers.





Raise the car. Install
- the oil return line. Use a new gasket and a new rubber sealing ring.
Remove the seal from the hole in the cylinder block.
Tighten the screw for the oil return line where it connects to the cylinder block. Tighten to 38 Nm
- the clamp between the turbocharger (TC) oil pressure pipe and the oil return line
- the splash guard under the engine





Lower the car. Install
- the charge air hose and the charge air pipe above the engine
- the heat deflector plate over the turbocharger (TC)
- the cross member. Tighten the screws at the suspension turret to 50 Nm and the screw for the engine bracket to 80 Nm.

Carry out a function test
Check the oil and coolant levels.