Replacing The Turbocharger (TC)

Replacing the turbocharger (TC)

Conditions

Remove:
- the air cleaner (ACL) housing assembly. See Replacing the air cleaner (ACL) Removal and Replacement
- the cover over the engine
- the rear engine cover
- the heat shield from the intake manifold and turbocharger (TC).

Removing the air hoses from the turbocharger (TC)




- Remove the hoses from the turbocharger (TC) control valve
- Slacken off the hose clamp and remove the air intake hose from the turbocharger (TC).

Removing the upper charge air pipe for the turbocharger (TC)





Remove:
- the cover over the connector
- the clamps. Remove the upper charge air pipe.

Draining the coolant
See Replacing coolant Removal and Replacement.

Removing the heat shield from the firewall




Remove the nuts. Lift off the heat shield.

Removing the oil and coolant hoses from the turbocharger (TC)






Remove:
- the upper and lower coolant hoses for the turbocharger (TC)
- the upper oil pipe for the turbocharger (TC)
- the clamp from the lower oil pipe
- the banjo bolt from the oil pipe on the engine side. Wipe up any spilled oil.

Removing heated oxygen sensors (HO2S)




Remove the upper heated oxygen sensor (HO2S). See Replacing lambda sonde front Removal and Replacement.

Removing the front exhaust pipe from the exhaust manifold




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

Removing the turbocharger (TC)




- Remove the mounting nuts securing the turbocharger (TC) to the exhaust manifold
- Remove the hoses from the turbocharger (TC) control valve. Mark up the hoses
- Remove the turbocharger from the exhaust manifold
- Carefully pull the return tube out of the cylinder block
- Remove the turbocharger (TC) by turning it
- Cover the openings on the engine
- Remove the gasket if applicable.

Removing turbocharger (TC) components





Remove:
- the two hoses
- the oil return line and the gasket
- the pipe bend
- the gasket if applicable.

Replacing the boost pressure control (BPC) valve
See Replacing the boost pressure control (BPC) valve Removal and Replacement.

Replacing the air bypass valve






Remove:
- the three screws
- the membrane and the cover.
Check the membrane valve.
Install the membrane and the cover.
Tighten the three screws.

Installing turbocharger (TC) components




- Clean the oil return line
- Install the oil return line with a new gasket on the turbocharger (TC)
- Install the 2 hoses)
- Clean the pipe bend surfaces carefully
- Install a new gasket
- Install the pipe bend.
Tighten to 45 Nm.

Installing the turbocharger (TC)




Clean the exhaust manifold mating surfaces carefully.
Install a new gasket on the mating surfaces for the exhaust manifold.
Install a new O-ring on the oil return line.
Install the turbocharger (TC) on the exhaust manifold.
Insert the oil return line in the cylinder block.
Tighten the nuts. Tighten to 45 Nm.

Installing the oil supply line for the engine and turbocharger (TC)





Note! Slacken off the pipe connection nut for the coolant pipe. Bend the pipe to one side. Then tighten the pipe connection nut. Tighten to 25 Nm.

Install new O-rings. Apply a little grease on the engine side.
Install the pipes with new O-rings on the turbocharger (TC).

Installing oil and coolant pipes





Install:
- the lower coolant pipe. Tighten the lower coolant pipe. Tighten to 25 Nm
- the upper coolant pipe. Tighten the upper coolant pipe. Tighten to 25 Nm
- the clamp on the oil pipe. Tighten the clamp.

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

Installing the heated oxygen sensor (HO2S)




Install the upper heated oxygen sensor (HO2S). See Replacing lambda sonde front Removal and Replacement.

Installing the front exhaust pipe




Install the front exhaust pipe.
Use a new gasket.
Tighten to 25 Nm.
Install the engine cover.

Installing the upper charge air pipe on the turbocharger (TC)





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

Installing the heat shield on the firewall




Install the heat shield. Tighten the nuts.

Installing the air intake hose




- Lubricate the air intake hose with a soap solution. Press the air intake hose into place on the turbocharger (TC). Tighten to 6 Nm
- Install the EVAP hoses
- Connect the connector
- Reinstall the vacuum hoses on the turbocharger (TC) control valve according to the markings.

Install:
- Install the air cleaner (ACL) assembly. See Replacing the air cleaner (ACL) Removal and Replacement
- Top up the cooling system. See Replacing coolant Removal and Replacement
- Check the adjustment of the turbocharger (TC). See Checking and adjusting the boost pressure control (BPC) valve on the turbocharger (TC) Adjustments
- Install the engine cover.