Replacing the Turbocharger (TC) Exhaust Manifold/Gasket

Replacing The Turbocharger (TC) Exhaust Manifold/Gasket

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 deflector plate over the turbocharger (TC)
- the charge air pipe over the engine
- the intake manifold for the turbocharger (TC).

- Detach the upper coolant return pipe from the turbocharger (TC). Clamp the coolant hose using lock grip pliers. Then place the pipe/hose to one side.
- Remove the oil inlet nipple.
- Raise the car.







- Remove:
- the clamp between the pipes
- the oil return line.
- the nuts for the exhaust manifold/turbocharger (TC).

- Apply lock grip pliers to the coolant inlet hose.
- Lower the car.

- Remove the Turbocharger (TC)
- Remove the coolant inlet pipe.
- Remove the nuts securing the turbocharger (TC)/exhaust manifold.
- Disconnect the hoses for:
- boost pressure (red).
- the by-pass valve (white).
- the pressure regulator (yellow).

- Remove:
- the turbocharger (TC).
- the old studs from the exhaust manifold.

- Remove the nuts holding the manifold to the cylinder head.







- Lift up the manifold.
- Clean the gasket faces and check that all studs are tightened.
- Install new gaskets.
- Install the manifold. Use new nuts and tighten to 25 Nm.
- Install:

NOTE: Ensure that there is no exhaust leakage.







- new studs (if any are missing). Tighten to 20 Nm.
- the turbocharger (TC).
- the hoses according to the marking.
- both the upper nuts for the exhaust manifold. Tighten them slightly.

- Raise the car.







- Install the lower nuts for the exhaust manifold. Tighten to 25 Nm.
- Tighten The Turbocharger (TC)







- Tighten the upper nuts for the exhaust manifold. Tighten to 25 Nm.
- Tighten the exhaust manifold to the turbocharger (TC).
- Tighten all the nuts. Tighten to 30 Nm and check that the surfaces are parallel.

- Raise the car.







- Install The Lower Oil Pipe
- Install the oil pipe. Use a new gasket and a new O-ring.
- Lubricate the O-ring.

- Lower the car.







- Install
- the oil inlet pipe.

NOTE: Install new copper washers for the coolant pipe and for the upper oil pipe.

- the clamp between the pipes.
- the inlet and outlet coolant pipes.

Remove the lock grip pliers.

- the fresh air intake hose.
- the inner heat deflector plate.
- the charge air pipe over the engine.
- the heat deflector plate over the turbocharger (TC).

- Raise the car.

Carry Out A Function Test:
- Test drive the engine.
- Check the boost pressure
- Check the oil and coolant levels.
- Wipe the engine compartment clean.
- Ensure that the steering wheel and gear selector lever are clean.