Turbocharger: Service and Repair
Turbocharger (TC), replacing
Special tools:
999 7076 Lever 999 7076 Lever
999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket
999 7057 Counterhold 999 7057 Counterhold
951 2953 Cover 951 2953 Cover
951 2957 Coolant Reservoir 951 2957 Coolant Reservoir
Note! The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.
Preparatory work
Removing components
Remove:
- the battery negative lead. See: Battery, disconnecting Battery Disconnecting
- the cross stay between the suspension turrets
- the charge air hose and the charge air pipe above the engine. Remove the hose clamp for the turbocharger (TC) intake pipe at the turbocharger (TC). Pull off the pipe from the connector. Place the pipe to one side. Mark up the vacuum hose for the turbocharger (TC) control valve
- the vacuum pipe for the pressure regulator
- the cable for the heated oxygen sensors (HO2S) from the clips and clamps
- the heat deflector plate from the turbocharger (TC).
Draining coolant
Raise the vehicle. See: Jacking points, body Service and Repair.
Remove the splash guard under the engine. Open the engine nipple. Drain the coolant into a container. Close the nipple.
Lower the vehicle.
Remove:
- the pipe screws for the upper coolant pipe on the turbocharger (TC). Fold the coolant pipe to one side
- the 2 x screws for the oil pressure line on the turbocharger (TC). Disconnect the oil pressure line. Discard the gasket
- the heated oxygen sensors (HO2S) from the exhaust pipe.
Removing the three-way catalytic converter (TWC)
Remove the three-way catalytic converter (TWC). See: Three-way catalytic converter (TWC), replacing, B5244T5, B5254T2 Service and Repair.
Removal
Disconnecting the front suspension components
Remove:
- the right-hand front wheel
- the center screw for the drive shaft.
Remove the nut for the ball joint and control arm. Counterhold the ball joint pinion so that the boot does not twist. Use a Torx wrench.
Note! Clean the exposed threads outside the nut. Spray using rust solvent before removing the nut.
Remove the engine splash guard.
Removing the drive shaft from the wheel hub
Fold down the control arm. Use lever: 999 7076 Lever 999 7076 Lever to move the wheel spindle to the side. At the same time, install protective sleeve 999 5562 on the ball joint pinion. Hold the sleeve in place using the nut for the ball joint.
Removing the drive shaft
Press out the wheel spindle. Detach the drive shaft from the hub. Do not damage the drive shaft boot. Use a tensioner band to pull the spring strut backwards. Remove the screws from the bearing cap for the drive shaft.
Caution! Do not pull the outer part of the shaft. Doing so could damage the axial stops in the joints.
Pull the drive shaft straight out.
Removing the propeller shaft
For AWD vehicles carry out the following work:
Mark the propeller shaft CV joint in relation to the bevel gear flange.
Remove the screws from the propeller shaft. Use: 999 7057 Counterhold 999 7057 Counterhold. Press the drive shaft joints together as much as possible. Remove the shaft from the bevel gear. Leave the end of the shaft resting against the anti-roll bar.
Removing bevel gear
Remove the 5 x screws for the bevel gear. Pull the bevel gear straight out. Then turn it during removal.
Removing the support bracket
Remove:
- the 3 x screws
- the bracket.
Removing components
Remove:
- the clamp between the turbocharger (TC) oil pressure line and the oil return line
- the screws where the oil return line connects to the turbocharger (TC). Pull the pipe from the cylinder block. Discard the gasket.
Note! Check that the rubber sealing ring comes away with the pipe. Seal the opening in the cylinder block.
Remove:
- the pipe screws where the coolant pipes are connected to the turbocharger (TC)
- the pipe screw for the oil pressure pipe in the engine block
Note! Collect any oil spilled under the pipe screws in the cylinder block
- the oil pressure pipe
- the coolant pipes for the turbocharger (TC). Place the pipes to one side
- the pipe screw where the oil pressure pipe connects to the turbocharger (TC). Place the pipe to one side.
Removing the turbocharger and exhaust manifold
Remove:
- the inner heat deflector plate from the manifold
- the nuts and washers holding the manifold to the cylinder head
- the manifold
- the old gasket residue. Clean the gasket faces. Check that all the studs are tightened.
Hint: Use rust solvent or similar on the studs.
Lower the turbocharger (TC)/exhaust manifold as one complete unit.
Note! Mark up the hoses on the turbocharger (TC) in a suitable way.
Installing the turbocharger/exhaust manifold
Remove the screws at the section between the turbocharger (TC) and the exhaust manifold. Discard the screws and gasket.
Installation
Note! For tightening torques, see: Tightening torque Tightening Torque.
Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling Service and Repair.
Installing the gasket
Install:
- a new gasket between the turbocharger (TC) and exhaust manifold
- the turbocharger (TC) to the exhaust manifold
- new screws and tighten.
Raise the turbocharger (TC) and exhaust manifold as one complete unit.
Note! Install the hoses on the turbocharger (TC) according to the marking.
Installing the turbocharger (TC) and exhaust manifold
Install:
- new gaskets
- the turbocharger (TC) and the exhaust manifold. Use new nuts at the manifold. Tighten
- the inner heat deflector plate.
Installing components
Install:
- the oil return line in the cylinder block with a new sealing ring
- the 2 x screws for the oil return line in the turbocharger (TC). Use a new gasket. Tighten. See: Tightening torque Tightening Torque
- the pipe screws for the coolant pipe. Use new copper washers. Tighten. See: Tightening torque Tightening Torque
- the oil pressure pipe on the turbocharger (TC)
- the pipe screw for the oil pressure pipe in the engine block and turbocharger (TC). Use new copper washers. Tighten. See: Tightening torque Tightening Torque
- the clamp between the turbocharger (TC) oil pressure pipe and the oil return line. Tighten.
Installing the bracket
Install:
- the bracket
- the 3 screws. Tighten. See: Tightening torque Tightening Torque.
Installing the bevel gear
Before installing the bevel gear, lubricate the spline joint between the transmission and the bevel gear. Use appropriate grease.
Ensure that the mating surfaces on the transmission and bevel gear are clean. Install the bevel gear. Lightly tighten the M10 screws alternately. Tighten.
Installing the propeller shaft
Check that the mating surfaces of the propeller shaft and flange are clean. Install the propeller shaft using the marking made earlier. Use new screws. Tighten. See: Tightening torque Tightening Torque.
Installing the three-way catalytic converter (TWC)
Install the three-way catalytic converter (TWC). See: Three-way catalytic converter (TWC), replacing, B5244T5, B5254T2 Service and Repair.
Installing the drive shaft and bearing cap on the pilot bearing for the shaft
Lubricate the mating surface at the end of the drive shaft. Use wheel bearing grease P/N 116 1241-3 (80 g). Install the drive shaft on the transmission and the mounting for the pilot bearing with the bearing cap and the 2 M8 screws. Tighten.
Installing the drive shaft
Note! Check that the seal on the end of the drive shaft is correctly positioned. See: Seal CV joint housing, replacing Seal CV Joint Housing, Replacing.
Press out the spring strut.
Align the drive shaft in the hub.
Remove the protective sleeve 999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket.
Locate the control arm on the ball joint pinion. Use: 999 7076 Lever 999 7076 Lever.
Install:
- the nut for the ball joint and control arm. Tighten to applicable specifications. Counterhold so that the ball joint boot does not rotate. Use a Torx wrench
- the drive shaft center screw. Use a new screw. Tighten to applicable specifications. Use a screwdriver as a counterhold on the brake disc.
Fitting the wheel
Install the wheel. See: Installing wheels Service and Repair
Installing components
Install:
- the screws for the oil pressure pipe. Tighten. See: Tightening torque Tightening Torque
- the pipe screws for the upper coolant pipe. Tighten. See: Tightening torque Tightening Torque
- the screws to the heat deflector plate above the turbocharger (TC). Tighten
- the upper charge air pipe. Tighten the screws and clamps. See: Tightening torque Tightening Torque.
Finishing
Checks
Fill with coolant. Use filling equipment: 951 2957 Coolant Reservoir 951 2957 Coolant Reservoir and cover 951 2953 Cover 951 2953 Cover.
Check the oil level in the engine and transmission. Start the engine and run the engine to normal operating temperature.
Check for any leakage.
Fill with fluids if necessary.