Vehicles with a diesel engine.
Removing
Attention! There is a risk of injury when jacking up and placing the vehicle on jack stands. Familiarize yourself with the safety precautions outlined in the chapter «car jacking».
1. Jack up the vehicle and place it on jack stands.
2. Remove mudguard (protection) engine, see relevant chapter.
3. Disconnect the air intake from the turbocharger by loosening the clamp.
4. Remove the intake manifold module, see relevant chapter.
5. Disconnect the front catalyst from the turbocharger and set it aside from the work site without removing the catalyst itself.
6. Disconnect the low pressure hose from the diaphragm valve on the turbocharger on the air intake side.
7. Disconnect the charge air hose from the turbocharger together with the noise reduction cover.
Attention! Place a suitable container under the turbocharger to collect the escaping oil.
8. Disconnect the oil supply line at the top of the turbocharger by unscrewing the hollow bolt and removing it along with the seals.
9. Disconnect the oil return line from the bottom of the turbocharger by unscrewing the two hex socket head bolts and removing the gasket.
10. Disconnect the support bracket and heat shield from the turbocharger. Carefully bend the shield up 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 up.
Installation
13. Clean the sealing surfaces of the turbocharger and exhaust manifold.
14. Connect the turbocharger and exhaust manifold by screwing in the mounting bolts and tightening them to 21 Nm.
15. Attach the support bracket and heat shield to the turbocharger by tightening the mounting bolts to 21 Nm.
Attention! To keep the support bracket free of stress, first loosen the second mounting bolt, and after attaching the bracket, tighten it.
16. Connect the oil outlet line to the bottom of the turbocharger with a new gasket. Tighten the oil line bolts with a force of 9 Nm.
17. Connect the oil supply line to the top of the turbocharger by installing new sealing rings and tightening the hollow bolt with a force of 25 Nm.
18. Fasten the charge air hose to the turbocharger together with a soundproof cover with a bolt tightening torque of 9 Nm.
Before installing, inspect the O-ring to make sure it is not damaged or porous. If necessary, replace the ring with a new one.
19. Connect the low pressure hose to the diaphragm valve.
20. Attach the front catalyst to the turbocharger, see relevant chapter.
21. Install the intake manifold module, see relevant chapter.
22. Fasten the air intake to the turbocharger, checking the condition of the connecting clamp before installation and, if necessary, replacing it with a new one. Install the clamp so that the head of the bolt is facing up.
23. Replace the engine protection, see relevant chapter.
24. Lower the car onto its wheels.
25. Check the engine oil level and add oil if necessary.