Procedures

Prerequisites
Remove:
- The complete Air Cleaner (ACL), see Replacing the Air Cleaner (ACL), refer to Air Cleaner Housing, Service and Repair.
- the engine cover
- the rear engine splash guard
- the heat shield from inlet manifold / Turbo Charger (TC).

Remove the air hoses from turbo charger (TC)





- Remove the hoses from the Turbocharger Control Valve (TCV)
- Unscrew the hose clamp and disconnect the air inlet hose from the turbo.

Remove turbocharger (TC) upper charge air pipe
Remove:





- the connector cover
- the clamps, and undo the upper charge air-pipe.

Draining coolant
See Replacing coolant, refer to Cooling System.

Remove heat shield from fireball





Remove the nuts and take the heat shield off.

Remove oil and water hoses from turbo charger (TC)
Undo:





- the upper and lower TC coolant pipes
- the upper TC oil pipe
- the clamp from the lower oil pipe
- the banjo bolt from the oil pipe at the engine side. Catch spilt oil.

Remove the two lambda sonds





Remove the two lambda sonds, see Replacing lambda sond front and Replacing lambda sond rear, refer to Computers and Control System, Oxygen Sensor.

Remove exhaust down pipe from exhaust manifold





- Remove the nuts
- Pull the exhaust down pipe downwards
- Remove the gasket.

Remove turbocharger (TC)





- Remove the TC exhaust manifold nuts
- Remove the hoses from the Turbocharger Control Valve (TCV). Mark the hoses
- Pull the Turbocharger (TC) from the exhaust manifold
- Pull the oil return pipe carefully out of the engine block
- Rotate the Turbocharger (TC) and remove it
- Seal the holes in the engine.

Remove parts from turbocharger (TC)
Remove:





- the two hoses
- the oil return pipe and the gasket
- the catalytic converter.

Replacing the Boost Pressure Control (BBC) valve
See Replacing Boot Pressure Control (BPC) valve, refer to Wastegate Actuator, Service and Repair.

Replacing the bypass valve
Remove:





- the three bolts
- the diaphragm and the cover.
Check the diaphragm valve.
Install the diaphragm and the cover.
Tighten the three bolts.

Installing parts on turbocharger (TC)
Install:





- the gasket and mount the oil return pipe on the Turbocharger (TC)
- the two hoses
- the catalytic converter.

Installing turbocharger (TC)





Clean the manifold surface carefully.
Position the Turbocharger (TC) on the exhaust manifold.
Install a new O-ring on the oil return pipe.
Push the oil return pipe into the engine block.
Tighten the nuts. Tightening torque 45 Nm.

Install catalytic converter





Install catalytic converter, see Replace catalytic converter, refer to Emission Control Systems.

Install oil supply pipe at engine side and turbo charger (TC)





Note! Undo the water pipe cap-nut and bend the pipe away. Tighten the cap nut afterwards to 25 Nm.

Install new rings on the bolt, use some grease on the engine.
Install the pipe with new rings on the turbo.

Install oil and coolant pipes
Install:





- the lower coolant pipe, tighten to 25 Nm
- the upper coolant pipe, tighten to 25 Nm
- the clamp on the oil pipe. Position the clamp.

Note! Use a new copper rings for coolant pipe and upper oil-pipes.

Install the two lambda sonds





Remove the two lambda sonds, see Replacing lambda sond front and Replacing lambda sond rear, refer to Computers and Control Systems, Oxygen Sensor.

Install exhaust down pipe
Install the exhaust down pipe.
Use a new gasket.
Tighten to 25 Nm.
Install the engine splash guard.

Install turbocharger (TC) upper charge air pipe
Install:





- the upper charge air pipe. Tighten to 6 Nm
- the connector cover.

Mount heat shield on firewall





Install the heat shield and tighten the nuts.

Install air inlet hose





- Apply soap and push the air inlet hose onto the Turbocharger (TC), tighten to 6 Nm
- Install the EVAP hoses
- Install the connector
- Install the vacuum hoses for the Turbocharger Control Valve (TCV) as marked.

Install:
- Install the complete Air Cleaner (ACL), see Replacing the Air Cleaner (ACL), refer to Air Cleaner Housing, Service and Repair.
- Fill the coolant system.
- Check the adjustment of the Turbocharger (TC), see Checking and adjusting boost pressure control valve on Turbocharger (TC), refer to Wastegate Actuator, Testing and Inspection.
- Fit the engine cover.