Installing Turbocharger

Information 

> Removing and installing recirculating air valve 

• If you are replacing the turbocharger, the existing recirculating air valve must be used. 

1. Install turbocharger.
   1. 1.1 Replace oil return line -1-  and holder.

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   Exploded view of oil return on turbocharger

2. Fit turbocharger.
   1. 2.1 Fit new gaskets on the exhaust flange.
   2. 2.2 Position turbocharger and exhaust pipe -2-  and make sure that the oil return line is fitted correctly.
   3. 2.3 Replace V-band clamp on exhaust pipe -4-  , fit it and tighten to > Tightening torque 20 Nm (14.8 ftlb.)  .
   4. 2.4 Replace fit-studs -1-  for exhaust pipes, fit nuts and tighten to > Tightening torque 15 Nm (11.1 ftlb.)  .
   5. 2.5 Screw on fastening nuts -1-  for exhaust pipes and tighten to > Tightening torque 25 Nm (18.4 ftlb.)  .

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   View of exhaust pipes

3. Fit catalytic converter.
   1. 3.1 Position catalytic converter, replace seal, fit V-band clamp -4-  and tighten to > Tightening torque 7 Nm (5 ftlb.) +/- 1 Nm (0.5 ftlb.)  .

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   Turbocharger overview II

4. Fit coolant pipes.
   1. 4.1 Replace O-rings on the coolant lines.
   2. 4.2 Insert coolant pipes.
   3. 4.3 Fit fastening screws -1-  and tighten to > Tightening torque 9 Nm (6.6 ftlb.)  .

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   Turbocharger overview I

5. Fit oil supply line.
   1. 5.1 Replace O-ring on oil supply line.
   2. 5.2 Insert oil supply line -3-  .
   3. 5.3 Fit fastening screw -2-  for oil supply line and tighten to > Tightening torque 9 Nm (6.6 ftlb.)  .

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   Turbocharger overview II

6. Fit active carbon filter line.
   1. 6.1 Replace O-ring.
   2. 6.2 Insert active carbon filter line -2-  .
   3. 6.3 Fit fastening screw -1-  and tighten to > Tightening torque 9 Nm (6.6 ftlb.)  .

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   Turbocharger at the side

7. Connect connections.
   1. 7.1 Connect and lock electric plug connection -2-  for recirculating air valve.
   2. 7.2 Connect vacuum hose -4-  to vacuum capsule -3-  .

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Turbocharger overview I