Replacing The Turbocharger (TC)

Turbocharger (TC), replacing

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).

Air hoses from the turbocharger (TC), removing

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

Turbocharger (TC) upper charge air pipe, removing

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

Coolant, draining
See Replacing coolant Removal and Replacement.

Heat shield from firewall, removing

Remove the nuts. Lift off the heat shield.

Turbocharger (TC), oil and coolant hoses, removing

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.

Heated oxygen sensors (HO2S) x2, removing

Remove the two heated oxygen sensors (HO2S). See Replace the front heated oxygen sensor (HO2S) Removal and Replacement and Replacing lambda sond rear Removal and Replacement.

Exhaust pipe front from exhaust manifold, removing

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

Turbocharger (TC), removing

- 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.

Turbocharger (TC) components, removing

Remove:
- the two hoses
- the oil return line and the gasket
- the three-way catalytic converter (TWC).

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

Air bypass valve, replacing

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

Turbocharger (TC) components, installing

Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling Flanged Joint, Assembling.

Install:
- the oil return line and a new gasket on the turbocharger (TC)
- the two hoses
- the three-way catalytic converter (TWC).

Turbocharger (TC), installing

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

Three-way catalytic converter (TWC), installing

Install the three-way catalytic converter (TWC). See Three-way catalytic converter (TWC), replacing Three-Way Catalytic Converter (TWC), Replacing.

Oil supply line to engine and turbocharger (TC), installing

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).

Oil and coolant pipes, installing

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.

Heated oxygen sensors (HO2S), x2, installing

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

Turbocharger (TC) upper charge air pipe, installing

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

Heat shield firewall, installing

Install the heat shield. Tighten the nuts.

Air intake hose, installing

- Lubricate the air intake hose using 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.