Turbocharger, Removing And Installing, 3.0L Engine: Installing

Install in reverse order of removal and note the following:

• When installing a new turbocharger compare the old and new components and if necessary reposition the attachments. Refer to OVERVIEW - TURBOCHARGER, 3.0L ENGINE .
• Replace the screw-type clamp and oil return line after removal.
• When installing a new turbocharger replace the coupling and screw-type clamp.
• Replace seals, gaskets, O-rings and self-locking nuts after disassembly.
• Replacing the stud bolts.
• Fill the turbocharger with engine oil at the oil supply line connection.
• Secure all hose connections with hose clamps that match the ones used in series production. Refer to the Parts Information.
• Check the vacuum hoses for damage before the assembly and replace if necessary.
• Used coolant cannot be used again.

If the Turbocharger was Replaced

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-- Assemble the new coupling -1- with a new screw-type clamp -2- on the turbocharger -3- as shown.

-- Tighten the screw-type clamp -2- until the turbocharger can be moved on the turbocharger.

Continuation for All

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-- Bring the oil return line -1- in the installation position and secure using the clip -arrow-.

-- Bring the turbocharger into the installation position and at the same time guide the oil return line to the cylinder block.

-- Tighten the stud bolts and nuts -arrows-.

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-- Install the stud bolts -arrows- and tighten them.

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-- Tighten the nuts -3-.

If the Turbocharger was Replaced

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-- Tighten the screw-type clamp at the same time push the coupling by hand in the direction of the -arrow-.

• The force must have an effect at the right angle to the coupling -arrow-.

-- When tightening pay attention that the flange contour of the coupling -1- is positioned flush to the contour on the turbocharger turbine housing.

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Further installation is the reverse order of removal.

-- Install the upper air duct pipe. Refer to AIR DUCT PIPE, REMOVING AND INSTALLING .

There may be additional procedures depending on the model. Refer to TURBOCHARGER, REMOVING AND INSTALLING .

-- Fill the coolant. Refer to COOLANT, DRAINING AND FILLING .

-- Tighten the nuts -item  15 and -item  20. This step is necessary to compensate for the shrinkage of the turbocharger compound.

-- Install the catalytic converter or catalytic converter with particulate filter. Refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING .

-- Check the oil level. Refer to ENGINE OIL .

-- Install the heat shield and engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

After installing the turbocharger, let the engine idle for approximately one minute without increasing the engine speed. This ensures adequate oil supply to the turbocharger.