Contents: Removal ↡ Installation ↡
Cars with diesel engines.
Removal
Warning! Jacking up and jacking up a vehicle may present a risk of injury. Read the safety precautions in Chapter "Jacking up a car".
1. Jack up the car and place it on jack stands.
2. Remove the engine splash guard, see the relevant chapter.
3. Disconnect the air intake from the turbocharger by loosening the mounting clamp.
4. Remove the intake manifold module, see the relevant chapter.
5. Disconnect the front catalytic converter from the turbocharger and set it aside from the work area without removing the catalytic converter itself.
6. Disconnect the low pressure hose from the diaphragm valve on the turbocharger side on the air intake side.
7. Disconnect the boost air hose from the turbocharger together with the noise-suppressing cap.
Caution: Place a suitable container under the turbocharger to collect any leaking oil.
8. Disconnect the oil feed line from the top of the turbocharger by unscrewing the hollow bolt and removing it along with the sealing gaskets.
9. Disconnect the oil return line from the bottom of the turbocharger by unscrewing the two Allen head bolts and removing the sealing gasket.
10. Disconnect the support bracket and heat shield from the turbocharger. Carefully bend the shield upwards to provide access to the exhaust manifold mounting bolts.
11. Disconnect the turbocharger from the exhaust manifold by unscrewing the mounting bolts.
12. Remove the turbocharger by pushing it upwards.
Installation
13. Clean the sealing surfaces of the turbocharger and exhaust manifold.
14. Connect the turbocharger and the exhaust manifold by screwing in the mounting bolts and tightening them to 21 Nm.
15. Secure the support bracket and heat shield to the turbocharger by tightening the mounting bolts to 21 Nm.
Caution: To ensure that the support bracket is tension-free, first loosen the second mounting bolt and then tighten it after connecting the bracket.
16. Connect the oil return line to the bottom of the turbocharger, installing a new sealing gasket. Tighten the oil line bolts to 9 Nm.
17. Connect the oil feed line to the top of the turbocharger, installing new O-rings and tightening the hollow bolt to 25 Nm.
18. Secure the boost air hose to the turbocharger together with the anti-noise cap, tightening the bolts to a torque of 9 Nm.
Before installation, inspect the sealing ring and make sure it is not damaged or porous. Replace the ring with a new one if necessary.
19. Connect the low pressure hose to the diaphragm valve.
20. Secure the front catalytic converter to the turbocharger, see the corresponding chapter.
21. Install the intake manifold module, see the relevant chapter.
22. Secure the air intake to the turbocharger, checking the condition of the connecting clamp before installation and replacing it with a new one if necessary. Install the clamp so that the bolt head faces up.
23. Install the engine protection back in place, see the relevant chapter.
24. Lower the car onto its wheels.
25. Check the engine oil level and add oil if necessary.