Turbocharger, Exhaust Manifold/Gasket, Replacement

Turbocharger, exhaust manifold/-gasket, replacement.

Note! As the illustrations in this service information are used for different model years and/or models, some variation may occur. However, the essential information in the illustrations is always correct.

Remove:




- the heat shield plate over the turbo.
- the charge-air pipe over the engine.
- inlet pipe for turbo.
Loosen the turbocharger's upper pipe for return coolant, clamp the coolant hose using pliers, then put the pipe/hose aside.
Loosen inlet-oil pipe's nipple.
Raise the car .

Remove:




- the clamp between the pipes.
- the oil return line.
- the nuts exhaust manifold-turbocharger.
Place clamping pliers on the hose by the coolant inlet.
Lower the car.

Loosen the turbocharger
Loosen the inlet-coolant pipe.
Remove the nuts, turbocharger-exhaust manifold.

Loosen hoses for:




- charge pressure (red-marked).
- relief valve (white-marked).
- pressure box (yellow-marked).

Remove:
- turbocharger.
- the old studs from the exhaust manifold.
Remove the nuts that hold the manifold to the cylinder head.
Lift up the manifold.
Clean the gasket surfaces and check that all studs are tightened.
Install new gaskets.
Install the manifold. Use new nuts
and tighten with 25 Nm .

Install:

Note! For tightening torques, see: Tightening torque, B5234T9 Tightening Torque.

Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling Service and Repair.




- new studs (if any are missing) are tightened with 20 Nm .
- the turbo unit.
- hoses according to marking.
- the exhaust manifold's both upper nuts, and tighten slightly.
Raise the car.

Install:




- the exhaust manifold's lower nuts.
Tighten with 25 Nm .

Tighten down the turbocharger




Tighten down the exhaust manifold's upper nuts
with 25 Nm .
Tighten down the exhaust manifold-turbocharger.
Tighten all nuts with 30 Nm
and check at the same time that the faces are parallel.
Raise the car .

Install lower oil pipe




Install the oil pipe with new gasket and new O-ring .
Lube the O-ring.
Lower the car .

Install:




- the oil inlet pipe.

Note! Install new copper washers for coolant pipes and for upper oil pipe.

- the clamp between the pipes
- the coolant pipes, for inlet and outlet.
Remove the clamping pliers.
- the fresh air intake hose.
- inner heat shield plate.
- the charge air pipe over the engine.
- the heat shield plate over the turbo.
Raise the car .


Test the function:
Test drive the engine.
Check the boost pressure Wastegate valve, adjusting, B5234T9, B5244T7 Adjustments.
Check oil and coolant levels.
Wipe the engine compartment clean.
Ensure that the steering wheel and gear selector lever are clean.