To fit

Fit a new gasket.
Apply 30 20 971 Screw-thread paste to the turbo and exhaust manifold studs.
Lift up and fit the turbo (B)
Tightening torque 24 Nm (18 lbf ft).
Fit new sealing washers, screw in the bolt for the turbo oil delivery pipe on the engine block (A) without tightening it.

Fig 1: Identifying Engine Block And Bolt
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Fit the turbo oil return pipe to the turbo with a new gasket and connect the pipe with a new O-ring, sparingly lubricated with Vaseline, non-acidic, to the connecting hole in the engine block. (B)
Tightening torque, oil return pipe to turbo 15 Nm (15 lbf ft)
Fit the coolant pipe between the turbo and the thermostat housing with new sealing washers (B).
Tightening torque 20 Nm (15 lbf ft).
Fit the stay (A) between the turbo and engine block. Fit the bolts by hand, start by tightening the bolts in the turbo.
Tightening torque, bolt in turbo 32 Nm (24 lbf ft)

Tightening torque, screw in block 48 Nm (35 lbf ft)

Fig 2: Identifying Stay And Sealing Washers
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Lower the car.
Fill with plenty of engine oil in the hole for the oil delivery connection on the turbo while turning the turbine wheel.
Fit the oil delivery pipe to the turbo and tighten the connection using new sealing washers. Grip the pipe so that it does not rotate. (A)
Tightening torque 28 Nm (21 lbf ft)

Fig 3: Identifying Coolant Pipe And Bypass Valve
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Position and fit the coolant pipe (B) to the turbo and tighten the pipe mounting on the cylinder head.
Connect the hose to the bypass valve (C).
Raise the car.
Tighten the oil delivery pipe connection on the engine block.
Tightening torque 28 Nm (21 lbf ft)
Lift up the catalytic converter, position its bracket to the studs on the engine block and position the catalytic converter to the turbocharger connection (A).

Fig 4: Identifying Engine Block With Nuts And Studs
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Insert the catalytic converter bracket bolts into the engine block and with new nuts for the studs (B).
Lower the car.
Lubricate the turbocharger studs with 30 20 971 Screw-thread paste
Fit the catalytic converter with new nuts (A) so that it rests evenly against the turbo.
Tightening torque 25 Nm (18 lbf ft)

Fig 5: Identifying Catalytic Converter Nuts
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Raise the car.
Tighten the catalytic converter nuts and bolts a last time.
Tightening torque, bolt 22 Nm (16 lbf ft) (A)

Tightening torque, nut 25 Nm (18 lbf ft) (B)

Fig 6: Identifying Catalytic Converter Nuts And Bolts
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Lubricate the threads sparingly with 30 20 971 Screw-thread paste and fit the lower oxygen sensor.
Tightening torque 40 Nm (30 lbf ft) (C)

IMPORTANT: Make sure cables to the oxygen sensor are not twisted or damaged.
Lift up the oxygen sensor cables.
IMPORTANT: Make sure the cables are not exerted to chafing.
Fit the heat shield (D) onto the catalytic converter.
Clean the joint on the catalytic converter and the pipe connection to the front silencer.
Mount the joint clamp and fit the front pipe with a new gasket, new nuts and rubber mountings. Lubricate the studs with 30 20 971 Screw-thread paste.
Move over the joint clamp so that the pipe ends are in the middle of the clamp.
Tighten the joint with the catalytic converter (A).
Tightening torque 25 Nm (18 lbf ft)

Fig 7: Identifying Catalytic Converter Joint
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Tighten the joint clamp nuts (B).
Tightening torque 40 Nm (30 lbf ft).
Fit the turbocharger pressure pipe (A).
CV : Fit Chassis reinforcement, front supporting frame, CV

Fig 8: Identifying Lower Turbocharger Pressure Pipe
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Fit the front spoiler shield. See SPOILER SHIELD , To fit.
Tightening torque 25 Nm (18 lbf ft)
Lower the car.
Lubricate the threads sparingly with 30 20 971 Screw-thread paste and fit the upper oxygen sensor (A). Fit the coolant reservoir.
Tightening torque 40 Nm (30 lbf ft).

Fig 9: Identifying Upper Oxygen Sensor
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Plug in and secure the oxygen sensor connectors (A).

Fig 10: Identifying Oxygen Sensor Connectors (A)
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Fit the vacuum box (A) to the turbo.

Fig 11: Identifying Vacuum Box, Control Rod And Crankcase Ventilation With Solenoid Valve Hoses
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Align the control rod (B) onto the control arm and fit the lock clip.
Fit the pipe for the crankcase ventilation (C).
Fit the solenoid valve hoses (D) to the turbo.
Fit the turbocharger heat shield (A).

Fig 12: Identifying Heat Shield, Casing Cover And Solenoid Valve
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IMPORTANT: To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressure, 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 the connecting pieces as well. If hose clips are rusty or damaged, they must be replaced so the correct clamping force is maintained.
Fit the air cleaner casing and connect the inlet hose to the turbo. Fit the filter and the air cleaner casing cover (B).
Fit the crankcase ventilation hose to the camshaft cover and turbo as well as the hose from the solenoid valve (C).
Fill with coolant to approx. 20 mm above the mark on the expansion tank.
Check for coolant leaks.
Check the oil and coolant level and top up as necessary.