Remove
- 1. Open bonnet
- 2. Disconnect battery • Detach ground connection from ground terminal – Undo nut
- 3. Remove air intake hose (1) • Undo 2x clamps (2)
- 4. Remove oil dipstick
- 5. Release top of oil dipstick guide tube • Unscrew bolt
- 6. Raise vehicle by half its height
- 7. Drain coolant • Place collecting basin underneath. • Open drain bolt on radiator (1) • Collect coolant – Use hose (2) • Close drain bolt
- 8. Raise vehicle by half its height
- 9. Drain engine oil
- 10. Detach charge air hose intercooler - turbocharger (1) from turbocharger • Release clamp (2)
- 11. Detach front exhaust pipe from catalytic converter • Unscrew 3x nut
Note. Attach exhaust system with flex pipe to vehicle underbody using suitable means, e.g. wire, or if necessary use a second person.
- 12. Remove oil dipstick guide tube (1) • Detach oil return hose from turbocharger • Withdraw oil dipstick guide tube from oil pan (2)
- 13. Detach turbocharger intake pipe (5) • Unscrew 2x bolts (6) • Lower vehicle by its full height • Detach wiring harness – Undo cable tie – Disconnect charge-air control wiring harness plug (3) • Detach cylinder head cover vent line (1) – Undo quick-release fitting • Pull off vacuum control for recirculating air (4) • Remove vacuum pipe from turbocharger (2) – Release clamp
- 14. Detach exhaust manifold heat shield • Unscrew 3x bolts (1)
- 15. Remove turbocharger heat shield
- 16. Remove extra catalytic converter (3) with oxygen sensor mixture control (2) and heat shield • Disconnect wiring harness plug of oxygen sensor mixture control (1) • Release clamp (4)
- 17. Detach turbocharger coolant return hose from turbocharger coolant return line • Release clamp
- 18. Detach oil supply hose from turbocharger (2) • Unscrew banjo bolt (1)
- 19. Pull vacuum line from turbocharger bypass valve
- 20. Remove coolant supply line to turbocharger (1) • Release clamp (3) • Unscrew bolt (2) • Unscrew banjo bolt (4)
- 21. Detach coolant feed hose (1) from coolant pipe (3) • Release clamp (2)
- 22. Detach exhaust manifold with turbocharger from cylinder head • Unscrew 9x nuts (arrows)
- 23. Clean sealing surfaces.
Install
- 24. Attach exhaust manifold with turbocharger to cylinder head • Tighten 9x new nuts in tightening sequence given 8 Nm • Tighten 9 nuts again in tightening sequence given 8 Nm
Note. Use new seal
- 25. Raise vehicle by its full height
- 26. Attach coolant supply line turbocharger to oil filter housing • Tighten 2x bolts
- 27. Install extra catalytic converter with oxygen sensor mixture control • Tighten clamp 7 Nm
- 28. Lower vehicle by its full height
- 29. Attach coolant feed hose to coolant pipe • Attach clamp
- 30. Attach turbocharger coolant feed line to turbocharger • Tighten banjo bolt 35 Nm
- 31. Attach vacuum line to turbocharger bypass valve
- 32. Attach turbocharger oil feed line to turbocharger • Tighten banjo bolt 30 Nm
- 33. attach turbocharger coolant return hose to turbocharger coolant return line • Fasten clamp
- 34. Connect wiring harness plug of catalytic converter monitor oxygen sensor
- 35. Install turbocharger heat shield • Screw in 2x bolts
- 36. Install dipstick guide tube • Screw in bolt
- 37. Tighten turbocharger heat shield bolts and oil dipstick guide tube 8 Nm
- 38. Install turbocharger intake pipe • Attach wiring harness – Attach cable tie – Connect charge-air control wiring harness plug • Attach cylinder head cover vent line – Connect quick-release fitting • Push on vacuum control for recirculating air • Attach vacuum line to turbocharger – Attach clamp
- 39. Raise vehicle by its full height
- 40. Attach turbocharger intake pipe • Tighten 2x bolt 8 Nm
- 41. Attach turbocharger oil return line to turbocharger • Tighten 2x bolt 8 Nm
- 42. Attach front exhaust pipe to catalytic converter • Tighten 3x new nuts • Detach flex pipe fixing tool
- 43. Attach charge air hose intercooler - turbocharger to turbocharger • Tighten clamp 3.5 Nm
- 44. Lower vehicle by its full height
- 45. Insert oil dipstick
- 46. Install air intake hose • Tighten 2x clamp 3.5 Nm
- 47. Connect battery
- 48. Program volatile memories
- 49. Cooling System, Charge and Bleed
- 50. Top up engine oil
- 51. Close bonnet