Turbocharger: Service and Repair

To Remove
1 Open the drain plug and drain out the coolant. Remove the lid of the expansion tank to speed up the draining.

2 Lift up the car and remove the air pipe and the hose between the turbocharger and the charge air cooler.

3 Undo the joint between the front exhaust pipe and the intermediate pipe and slightly undo the screw which holds the exhaust pipe to the securing point on the engine.

4 Remove the front exhaust pipe from the turbocharger and hang up the pipe so that the oxygen sensor's cable is not damaged.

5 Break the seal and remove the locking ring on the wastegate.

6 Remove the stay on the turbocharger and remove the oil return pipe. Plug the pipe with a rag.

7 Undo the oil pipe on the oil filter and lower the car.

8 Remove the hoses to the boost pressure control valve and make a note of how they were positioned.

9 Remove the intake hose with its bypass hose, undo the nuts to the wastegate's diaphragm unit and remove the intake pipe together with the crankcase ventilation pipe.

10 Remove the oil pipe to the turbocharger and remove the lower coolant pipe.

11 Undo the screw for the upper coolant pipe from the turbocharger.

12 Remove the turbocharger.





To Install
1 Clean all sealing surfaces and install the turbocharger.

Tightening torque 22 Nm (16 ft lbs).

2 Refit the coolant pipes and the oil pipe to the turbocharger.

3 Refit the turbocharger's intake pipe together with the crankshaft ventilation pipe. Tighten the nuts on the wastegate's diaphragm unit and connect the hoses from the boost pressure control valve.

4 Refit the intake hose with its bypass hose and lift up the car.

5 Connect the oil pipe to the oil filter and refit the return oil pipe.

6 Refit the locking ring for the wastegate and refit the stay between the turbocharger and the cylinder block.

7 Lubricate the three pin screws on the turbocharger with Molycote 1000 and refit the front exhaust pipe to the turbocharger. Pull the joint to the intermediate pipe together and tighten the screw which holds the catalytic converter to the securing point.

8 Refit the air pipe and the hose between the turbocharger and the charge air cooler. Lower the car.

9 Check that the radiator's drain plug is tightened. Fill up with coolant and check that the system does not leak.

10 Check the oil level and the quality of the oil.

11 Check the basic boost pressure, see "Checking the basic boost pressure (on road)", and adjust if necessary. Testing and Inspection

12 Re-seal the pressure rod.