To fit

Fig 1: Illustration For Steps 1-4

Courtesy of SAAB-SCANIA OF AMERICA, INC.

IMPORTANT: It is essential that there is oil in the turbo bearing housing when the engine is started. An extra check should be made when fitting a new turbo.
Fill the turbo oil inlet with oil from an oil can. Rotate the compressor wheel by hand many times to ensure that oil enters the bearings.

NOTE: Coat the studs thinly with Molycote 1000, part No. 30 20 971, or similar.

NOTE: Spray the connector with Anti-corrosion agent, Contact Protect before connecting.

Fit the turbo. Tighten only the two upper locknuts at the connection between the turbo and the front exhaust system.
Tightening torque: 24 Nm (18 lbf ft)

IMPORTANT: When fitting the front exhaust system to the turbo, the nuts should be tightened alternately to avoid distorting the flange. The flange must not abut against the turbo connection flange.
Fit the turbo coolant return pipe. Fit new copper washers.
Tightening torques

Nipple in cylinder head: 35 Nm (26 lbf ft)

Banjo screw, cylinder head: 25 Nm (18 lbf ft)

coolant return pipe/turbo 25 Nm (18 lbf ft)

Clamp, coolant return pipe 9 Nm (7 lbf ft)
Fit the coolant return pipe to the turbo. Also, tighten the pipe by the coolant pump. Fit new copper washers.
Tightening torques

Banjo screw, turbo: 25 Nm (18 lbf ft)

Banjo screw, coolant pump: 20 Nm (15 lbf ft)
Fit the turbo oil pipe (connection to the turbo). Use new copper washers.
Tightening torques

Banjo screw, turbo: 20 Nm (14 lbf ft)
Fit a new O-ring, greased with non-acidic Vaseline, on the turbo intake pipe. Fit the Vclamp on the pipe and position it. Bolt the pipe to the power steering pump bracket to facilitate tightening/fitting the V-clamp.

Fig 2: Illustration For Steps 5-11
Courtesy of SAAB-SCANIA OF AMERICA, INC.
Slacken the adjusting screw on the intake manifold to adjust the pipe.
Tighten the V-clamp between the turbo and the turbo intake pipe.
Tightening torque 3 Nm (2 lbf ft)
Tighten the intake manifold bolt in the power steering pump mounting. Also tighten the adjusting screw.
Tightening torque: 24 Nm (18 lbf ft)

IMPORTANT: To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressures, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 93 160 907 Motip Dupli cleaning agent to wipe clean inside the ends of the hoses. Clean also the connecting pieces. If hose clips are rusty or damaged, they must be replaced with new ones to maintain the correct clamping force.
Connect all the hoses to the turbo and the diaphragm housing.
Remove the plug from the charge air cooler inlet pipe.
Connect the charge air cooler's inlet hose to the turbo.
Tightening torque: 8 Nm (6 lbf ft)
Fit the heat shield. Press on the left-hand holder first. Apply Molycote 1000, part no. 30 20 971, to the stud.
Tightening torque: 20 Nm (15 lbf ft)
Fit the mass air flow sensor and air hose.

Fig 3: Illustration For Steps 13-17
Courtesy of SAAB-SCANIA OF AMERICA, INC.
Fit the engine lifting eye.
Screw the crankcase breather pipe's bolt in the camshaft cover and the banjo bolt in the turbo intake pipe.
Tightening torque: 24 Nm (18 lbf ft)

IMPORTANT: Fit the turbo intake pipe bolt with new copper washers.
Plug in the mass air flow sensor and boost pressure control valve connectors.
Connect the charge air bypass valve and pipe. Fit a new O-ring greased with nonacid Vaseline.
Tighten the bolts and fit the hose clip.
Tightening torque: 8 Nm (6 lbf ft)
Raise the car and fit the third nut at the connection between the turbo and the front exhaust system.

Fig 4: Illustration For Steps 19-22
Courtesy of SAAB-SCANIA OF AMERICA, INC.

Tightening torques:

Stud: 22 Nm (16 lbf ft)

Locknut 24 Nm (18 lbf ft)
Fit the turbo oil pipe (connection to oil filter adapter). Fit new copper washers.
Tightening torque: 25 Nm (18 lbf ft)
Fit the turbo stays.
Tightening torque: 24 Nm (18 lbf ft)
Fit the return oil connection and pipe from the turbo to the cylinder block. Lower the car.
Tightening torques

M6 bolts 2x, turbo: 14 Nm (10 lbf ft)
Fill up with coolant to MAX. Do not forget to close the drain cock on the radiator first. For the correct mixture, see COOLANT, 4-CYL. . Close the cap.

Fig 5: Illustration For Steps 23, 28
Courtesy of SAAB-SCANIA OF AMERICA, INC.
Start the engine and warm it up without load, preferably at varying speeds until the radiator fan cuts in.
Turn off the engine and top up with engine oil/coolant as necessary.
Raise the car.
Inspect the system for possible leaks.
Fit the lower front cover.
Lower the car to the floor.