Turbocharger

Turbocharger

Special tools, testers and auxiliary items required

• Hose Clamps Up to 25 mm Diameter (3094)

Removing

• All heat insulation sleeves removed during engine removal must be reinstalled at the same locations during installation.

- Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.





- Remove turbocharger bracket - 2 -.





- Remove oil return line - 1 - on the turbocharger and move it to the side.

- Disconnect air guide hoses - 4 - and - 5 - on the turbocharger.

- Remove pressure line banjo fitting - 3 -.

- Remove hose - 1 - on the boost pressure regulator valve vacuum diaphragm on the turbocharger.





- Clamp off the lower coolant supply hose on the turbocharger using a Hose Clamps Up to 25 mm Diameter (3094).

- Open the quick-release fasteners - arrows - and remove the engine cover.





- Remove right cover - 1 - in the engine compartment, if equipped.





- Disengage Evaporative Emission (EVAP) Canister Purge Regulator Valve (N80) from the air guide.

- Remove bolts - arrows -.





- Remove air duct - 2 -.

- Disconnect the connector - 3 - on the evaporative emission canister purge regulator valve (N80) and the connector - 5 - on the mass air flow sensor (G70).





- Disconnect hoses - 1 -, - 4 -, - 6 -, - 7 -.

- Remove the air filter housing by removing the expanding clip - 2 -.

- Remove the secondary air pipe while disconnecting the hoses - arrows - and bolts - 1 -.





- Remove heat shield - 3 - from the secondary air pipe - 1 - and from the cylinder head.





• Ignore - 2 -.

- Install sleeve on the coolant return hose.





- Clamp off the coolant return hose for the turbocharger using a Hose Clamps Up to 25 mm Diameter (3094).

- Loosen hose clamp - 4 - and disconnect the coolant return hose at the line for the turbocharger. The line remains connected to the turbocharger.

- Remove the oil supply line bolts - 1 - and - 3 -.





- Remove the oil supply line on the turbocharger - 5 -.

• Exhaust system decoupling element must not be bent more than 10°, otherwise it may be damaged.

- Remove catalytic converter/turbocharger bolts - 6 -.

- Remove turbocharger/exhaust manifold bolts - 2 -.

- Move turbocharger to the side, loosen the mounting bracket and the coolant supply line banjo bolt on the turbocharger.

- Remove turbocharger.

Installing

Installation is in reverse order of removal, note the following:

• Always replace gaskets, seals and self-locking nuts.

• Hose connections and charge air system hoses must be free of oil and grease before installing.

• During installation, re-install all heat insulation sleeves at the same locations.

• Secure all hose connections using hose clamps appropriate for the model type.

- Perform the following steps before tightening the turbocharger:

- Secure the loose coolant supply line with the bracket on the boost pressure regulator valve vacuum diaphragm.

- Tighten the banjo bolt to 35 Nm and then tighten the bracket bolt to 10 Nm.

• Fill the turbocharger with engine oil at the oil supply line connection.

- Check oil level. Refer to => [ Oil Level, Checking ] .

- Fill with coolant => [ Filling ] Cooling System, Draining and Filling.

• After installing turbocharger, let engine idle for approximately 1 minute without increasing engine speed. This ensures adequate oil supply to the turbocharger.

Tightening Specifications





* Replace bolts.

* Coat the thread and head contact surfaces with hot bolt paste.