Installing (engine codes 1Z, AHU)
WARNING: This page is about a different car, the 1996 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.
- Install blue wastegate hose on turbocharger and secure with clamp.
- Grease threads of mounting bolts -2- and head contacting surfaces with high temperature (2000°F) anti-seize compound.
- Install turbocharger on exhaust manifold and tighten mounting bolts -2- finger-tight.
- Install mounting nut -1- and tighten.
Tightening torque: 20 Nm (15 ft lb)
- Tighten mounting bolts -2-.
Tightening torque: 35 Nm (26 ft lb)
- Install turbocharger to cylinder head support.
Tightening torque: 25 Nm (18 ft lb)
- Install oil return pipe with new seal and tighten.
Tightening torque: 30 Nm (22 ft lb)
- Install front exhaust pipe with new gasket onto flange and tighten.
Tightening torque: 25 Nm (18 ft lb).
- Fill turbocharger with engine oil via oil supply connection.
- Install oil supply line.
Tightening torque: 25 Nm (18 ft lb)
- Tighten oil supply line support to: 10 Nm (7 ft lb).
- Install red hose for wastegate bypass regulator valve -N75- on turbocharger and secure with clamp (or banjo bolt with new seal) and tighten.
Tightening torque: 15 Nm (11 ft lb)
- Install O-ring onto intake pipe, then install pipe to turbocharger and tighten.
Tightening torque: 10 Nm (7 ft lb)
- Install pressure line.
CAUTION:
After installing the turbocharger, let engine idle for approx. 1 minute. DO NOT rev-up the engine at first! (This ensures that the turbocharger is properly lubricated.)