Installing Turbocharger

Information 

The procedure for removing and installing is described for one side as an example. The procedure for the other side is practically identical.

Information 

• Replace O-rings on the cooling system. 
• Clean plug connection and coolant hoses before assembly. 
• Remove stoppers before fitting the coolant lines and hoses. 

Information 

• O-rings must always be replaced. 
• O-rings must be coated lightly with Kluber Syntheso Glep. 

1. Replace seal -1-  at the connection point of the turbocharger and the catalytic converter.

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   Turbocharger/catalytic converter seal

2. Secure the catalytic converter -1-  .

   Position the catalytic converter and clamping sleeve in installation position.

   Tighten screws -2-  on the support.

   Tightening torque: > Tightening torque 23 Nm (17 ftlb.) +/- 10 % 

   Tighten nuts -3-  on the clamping sleeve.

   Tightening torque: > Tightening torque 30 Nm (22 ftlb.) +/- 10 % 

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   Catalytic converter

3. Fix turbocharger to the exhaust manifold.

   Insert new seal -2-  .

   Coat studs with MicroGLEIT LP 475  .

   Position turbocharger in installation position.

   Tighten new nuts -1-  .

   Tightening torque: > Tightening torque 25 Nm (19 ftlb.) 

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   Turbocharger on exhaust manifold

4. Attach turbocharger to the catalytic converter.

   Fit new V-band clip -1-  on the catalytic converter.

   Tighten screw -2-  .

   Tightening torque: > Tightening torque 20 Nm (15 ftlb.) 

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   V-band clip for catalytic converter/turbocharger

5. Connect cable plug -1-  to electronic adjuster.

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   Cable plugs for electronic adjuster

6. Secure oil line (pressure side)-1-  .

   Replace O-rings.

   Tighten screw -2-  .

   Tightening torque: > Tightening torque 10 Nm (7.5 ftlb.) 

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   Oil line (pressure side)

7. Secure coolant lines -1-  and -2-  .

   Replace O-rings.

   Secure holder -4-  .

   Tighten screw -3-  .

   Tightening torque: > Tightening torque 10 Nm (7.5 ftlb.) 

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   Coolant lines for turbocharger

8. Secure tank vent line -1-  .

   Replace O-rings.

   Tighten screw -2-  .

   Tightening torque: > Tightening torque 10 Nm (7.5 ftlb.) 

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   Turbocharger tank vent line

9. Disconnect oil line (intake side) -1-  .

   Replace O-rings.

   Insert oil line -1-  into the turbocharger.

   Fit screws -2-  .

   Secure support -3-  , to do this, fit a screw -4-  .

   Tighten screw -2-  .

   Tightening torque: > Tightening torque 10 Nm (7.5 ftlb.) 

   Tighten screw -4-  .

   Tightening torque: > Tightening torque 10 Nm (7.5 ftlb.) 

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   Oil line (intake side)

10. Secure vent line -1-  .

    Replace O-rings.

    Tighten screw -2-  .

    Tightening torque: > Tightening torque 10 Nm (7.5 ftlb.) 

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    Turbocharger vent line

11. Fit intake line -1-  to turbocharger.

    Replace O-ring.

    Fit the new V-band clip.

    Tighten screw -2-  .

    Tightening torque: > Tightening torque 5.5 Nm (4 ftlb.) +/- 0.2 Nm (0.1 ftlb.) 

    Tighten new screw-type clamp -3-  .

    Tightening torque: > Tightening torque 5.5 Nm (4 ftlb.) +/- 0.2 Nm (0.1 ftlb.) 

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    Intake pipe on turbocharger

12. Fit pressure hose -1-  on turbocharger.

    Tighten screw-type clamps -2-  .

    Tightening torque: > Tightening torque 5.5 Nm (4 ftlb.) +/- 0.2 Nm (0.1 ftlb.) 

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Pressure hose for turbocharger