Removing
1. Disconnect the negative battery terminal.
2. Disconnect the #1 heated oxygen sensor electrical connector.
3. Raise and secure the car.
4. Remove the drain plug and drain the engine oil.
Note. After draining the engine oil, install the drain plug with a new O-ring.
5. Remove the intercooler inlet hose.
6. Remove the turbocharger oil return hose.
7. Remove the front exhaust pipe.
8. Remove the catalytic converter.
9. Lower the car.
10. Open the drain hole of the cooling system.
11. Remove the air filter assembly.
12. Remove the tensile drive belt (1) from power steering pump (2).
13. Remove the three mounting bolts (3) power steering pump.
Note. Secure the power steering pump with a wire loop.
14. Remove the turbocharger flap control solenoid valve.
15. Remove the turbocharger air intake adapter:
- Loosen clamp (3) and remove the tube (1) bypass valve (2) boost.
- Loosen the clamp and remove the hose (2) from the turbocharger damper actuator (3).
- Loosen the clamp and remove the turbocharger throttle control solenoid valve hose (5) with turbocharger (4).
- Loosen two screws (6) turbocharger air intake pipe.
- Remove air intake pipe (1) turbocharger.
- Remove and discard gasket.
16. Loosen the bolt (1) and remove the oil dipstick guide tube.
17. Remove the two exhaust manifold heat shield bolts.
18. Remove the vacuum hose from the turbocharger.
19. Remove the vacuum hose from the turbocharger.
20. Remove the hose from the turbocharger cooling return pipe.
21. Remove the coolant pressure pipe from the turbocharger.
22. Remove pressure oil line (2) from the turbocharger.
Note. After removing the exhaust manifold assembly, turn the turbocharger oil pressure line 90 to disengage the retainer (3).
23. Unscrew the hollow bolt (1) turbocharger pressure oil line with two O-rings (4).
24. Unscrew the nine nuts of the turbocharger (1).
25. Remove the turbocharger gasket (2).
26. Remove the turbocharger (4).
27. Remove the exhaust manifold gasket (3).
28. Remove the cooling return pipe banjo bolt from the exhaust manifold assembly.
Installation
1. Clean the contact surface of the exhaust manifold.
2. Install a new exhaust manifold gasket (2) to the exhaust manifold.
3. Install the banjo bolt with new O-rings and secure the exhaust manifold cooling return pipe assembly.
4. Install the turbocharger pressure oil line with a new O-ring.
Note. Insert the turbocharger oil pressure line into the port and turn 90°.
5. Install turbocharger (3).
6. Install nine new nuts (1) and tighten to 8 Nm.
7. Install pressure oil line (2) to the turbocharger.
8. Install the hollow bolt of the turbocharger pressure oil line (1) with two new O-rings (4) and tighten to 30 Nm.
9. Install the cooling supply line to the turbocharger.
10. Install the return hose to the turbocharger cooling return pipe.
11. Install and hand-tighten the two exhaust manifold heat shield nuts.
12. Install the oil dipstick guide tube with two new O-rings.
13. Install the oil dipstick guide tube mounting bolt (1) and tighten to 8 Nm.
14. Tighten the exhaust manifold heat shield fasteners to 8 Nm.
15. Install the turbocharger flap control solenoid valve to the turbocharger air intake adapter.
16. Install the turbocharger air intake adapter.
17. Install the vacuum hose on the turbocharger.
18. Install the power steering pump (2).
19. Install three bolts (3) power steering pump and tightened to 22 Nm.
20. Install the tension drive belt (1) to the power steering pump:
- Install fixture EN-50098 (1) and stretch drive belt (2) on a pulley (3) power steering pump, then slowly turn the engine crankshaft clockwise.
Note. When rotating the engine crankshaft, make sure that the belt is correctly installed on the water pump pulley.
- Remove tool EN-50098.
21. Install the air filter assembly.
22. Connect the electrical connector to the turbocharger flap control solenoid valve.
23. Raise the car.
24. Install the turbocharger oil return hose.
25. Install the intercooler air inlet hose.
26. Install catalytic converter.
27. Install the front exhaust pipe,
28. Lower the car.
29. Connect the #1 heated oxygen sensor electrical connector.
30. Connect the negative battery terminal.
31. Fill the engine with engine oil.
32. Fill the engine cooling system.
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