Turbocharger: Service and Repair
Turbocharger (TC), replacing
Special tools:
999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket
999 7076 Lever 999 7076 Lever
999 7057 Counterhold 999 7057 Counterhold
951 2953 Cover 951 2953 Cover
951 2957 Coolant Reservoir 951 2957 Coolant Reservoir
Note! 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.
Preparatory work
Removing components
Remove:
- the cross stay between the suspension turrets
- the charge air hose and the charge air pipe above the engine. Remove the hose clamps for the turbocharger (TC) intake pipe at the turbocharger (TC). Pull off the pipe from the connector. Place the pipe to one side.
Raise the vehicle. See: Jacking points, body Service and Repair.
Draining coolant
Remove the splash guard under the engine. Open the engine nipple. Drain the coolant into a container. Close the nipple. Lower the vehicle.
Removal
Removing components from the turbocharger (TC)
Mark up the vacuum hose for the pressure regulator on the turbocharger (TC).
Remove:
- the vacuum hose from the pressure regulator on the turbocharger (TC)
- the cable for the heated oxygen sensors (HO2S) from the clips and clamps
- the upper heat deflector plate from the turbocharger (TC)
- the pipe screw for the oil pressure pipe in the turbocharger (TC). Discard the gaskets
- the pipe screws for the upper coolant pipe from the turbocharger (TC). Discard the gaskets.
Disconnecting the front suspension components
Remove:
- the right-hand front wheel
- the screw for the drive shaft / wheel hub.
Disconnecting the front suspension components, continued
Note! Clean the exposed threads outside the nut. Spray using rust solvent before removing the nut.
Remove the nut for the ball joint and control arm. Counterhold the ball joint pinion so that the boot does not twist. Use a Torx wrench.
Removing the drive shaft from the wheel hub
Fold down the control arm. Use lever 999 7076 Lever 999 7076 Lever to move the wheel spindle to the side. At the same time, install protective sleeve 999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket on the ball joint pinion. Hold the sleeve in place using the nut for the ball joint.
Removing the drive shaft
Caution! Do not pull the outer part of the shaft. Doing so could damage the axial stops in the joints.
Press out the wheel spindle. Detach the drive shaft from the hub. Do not damage the drive shaft boot. Use a tensioner band to pull the spring strut backwards. Remove the screws from the bearing cap for the drive shaft. Pull the drive shaft straight out.
Removing the propeller shaft
For AWD vehicles carry out the following work:
Remove the front member from the car body.
Remove the brake pipe from the mountings in the member. Mark the propeller shaft CV joint in relation to the bevel gear flange.
Remove the screws from the propeller shaft. Use: 999 7057 Counterhold 999 7057 Counterhold. Press the drive shaft joints together as much as possible. Remove the shaft from the bevel gear. Leave the end of the shaft resting against the anti-roll bar.
Removing bevel gear
Remove the 5 x screws for the bevel gear. Pull the bevel gear straight out. Then turn it during removal.
Removing the three-way catalytic converter (TWC)
Remove the three-way catalytic converter (TWC). See: Three-way catalytic converter (TWC), replacing, B5244T5, B5254T2 Service and Repair.
Removing the support bracket
Remove:
- the 3 x screws
- the bracket.
Removing components from the turbocharger (TC)
Remove:
- the clamp between the turbocharger (TC) oil pressure line and the oil return line
- the screws where the oil return line connects to the turbocharger (TC). Pull the pipe from the cylinder block.
Note! Check that the rubber sealing ring comes away with the pipe. Seal the opening in the cylinder block.
Remove:
- the pipe screws for the lower coolant pipe from the turbocharger (TC). Discard the gaskets
- the pipe screw for the oil pressure pipe in the engine block. Discard the gaskets.
Note! Collect any oil spilled under the pipe screws in the cylinder block.
Remove the oil pressure pipe.
Removing the turbocharger (TC) and exhaust manifold
Hint: Use rust solvent or similar on the studs.
Remove:
- the inner heat deflector plate from the manifold
- the nuts and washers holding the manifold to the cylinder head
- the manifold
- the old gasket residue. Clean the gasket faces. Check that all the studs are tightened.
Lower the turbocharger (TC) and exhaust manifold as one complete unit.
Note! Mark up the hoses on the turbocharger (TC) in a suitable way.
Installation
Note! For tightening torques, see: Tightening torque Tightening Torque.
Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling Service and Repair.
Assembling the turbocharger (TC)
Install:
- a new gasket between the turbocharger (TC) and exhaust manifold
- the turbocharger (TC) to the exhaust manifold
- new screws and tighten.
Note! Install the hoses on the turbocharger (TC) according to the marking.
Raise the turbocharger (TC) and exhaust manifold as one complete unit.
Installing the turbocharger and exhaust manifold
Install:
- new gaskets
- the turbocharger (TC) and the exhaust manifold. Use new nuts at the manifold. Tighten
- the inner heat deflector plate.
Installing components on the turbocharger (TC)
Install:
- the oil pressure pipe in the cylinder block with the pipe screw. Use new gaskets. Do not tighten
- the oil return line in the cylinder block with a new sealing ring
- the 2 x screws for the oil return line in the turbocharger (TC). Use a new gasket. Tighten
- the lower and upper coolant pipe and pipe screws. Tighten. See: Tightening torque Tightening Torque
- the clamp between the oil pressure pipe and the return pipe. Tighten.
Installing the bracket
Install:
- the bracket
- the 3 screws. Tighten. See: Tightening torque Tightening Torque.
Installing the bevel gear
For AWD vehicles carry out the following work:
Before installing the bevel gear, lubricate the spline joint between the transmission and the bevel gear. Use appropriate grease.
Ensure that the mating surfaces on the transmission and bevel gear are clean. Install the bevel gear. Lightly tighten the M10 screws alternately. Tighten.
Installing the propeller shaft
Check that the mating surfaces of the propeller shaft and flange are clean. Install the propeller shaft using the marking made earlier. Use new screws. Tighten the screws. See: Tightening torque Tightening Torque.
Installing the three-way catalytic converter (TWC)
Install the three-way catalytic converter (TWC). See: Three-way catalytic converter (TWC), replacing, B5244T5, B5254T2 Service and Repair.
Installing the drive shaft and bearing cap on the pilot bearing for the shaft
Lubricate the mating surface at the end of the drive shaft. Use wheel bearing grease P/N 1161 241-3 (80 g). Install the drive shaft on the transmission and the mounting for the pilot bearing with the bearing cap and the 2 M8 screws. Tighten.
Installing the drive shaft
Caution! Check that the seal on the end of the drive shaft is correctly positioned. See: Seal CV joint housing, replacing Seal CV Joint Housing, Replacing.
Press out the spring strut. Align the drive shaft in the hub. Remove protective sleeve. Use: 999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket. Locate the control arm on the ball joint pinion. Use: 999 7076 Lever 999 7076 Lever.
Install:
- the nut for the ball joint and control arm. Tighten to applicable specifications. Counterhold so that the ball joint boot does not rotate. Use a Torx wrench
- the drive shaft center screw. Use a new screw. Tighten to applicable specifications. Use a screwdriver as a counterhold on the brake disc.
Installing the components engine compartment
Install:
- the pipe screw together with new gaskets on the oil pressure pipe in the turbocharger (TC). Tighten
- the upper heat deflector plate. Tighten the screws
- the charge air pipe over the engine
- the cross stay between the suspension turrets
- the tie strap for the servo cable in the cross stay. Raise the vehicle. See: Jacking points, body Service and Repair.
Finishing
Routing the joint
Tighten the pipe screws for the oil pressure pipe in the cylinder block. See: Tightening torque Tightening Torque.
Installing components
Install:
- the lower engine cover
- the right-hand front wheel. See: Installing wheels Service and Repair.
Check
Fill with coolant. Use the filling equipment: 951 2957 Coolant Reservoir 951 2957 Coolant Reservoir and cover 951 2953 Cover 951 2953 Cover.
Start the engine and run the engine to normal operating temperature.
Check the function. Check for leaks. To up the coolant to max if necessary.