Turbocharger

K9K

Tightening torques
turbocharger exhaust manifold nuts	2.6 daN.m
side support bracket mounting screw	2.5 daN.m
rear catalytic converter mounting screw	2.1 daN.m
side support bracket mounting screw on the engine	4.4 daN.m
turbocharger mounting screw on the exhaust manifold	2.6 daN.m
exhaust gas recirculation solenoid valve heat shield mounting screw	1.2 daN.m
turbocharger oil supply pipe fitting	2.3 daN.m
turbocharger oil supply pipe fitting on the cylinder head	2.3 daN.m
turbocharger oil return pipe on the turbocharger	1.2 daN.m
turbocharger mounting studs on the exhaust manifold	0.9 daN.m
turbocharger mounting studs on the turbocharger	0.9 daN.m

REMOVAL

• Position the vehicle on a two-post lift.
• Remove the engine covers.
• Disconnect the battery.
• Remove the engine undertray.

• Disconnect the air duct (1).
• Remove the air duct (2) from the turbocharger.
• Disconnect:

• the boost pressure sensor (3),
• the exhaust gas recirculation solenoid valve (4),
• the boost pipe (5) from the turbocharger,
• the rubber hose (6) from the boost pressure control valve to the air duct.

• Remove:

• the exhaust flange fasteners (7),
• the support bracket (8) fastener on the catalytic converter.

• Loosen the other support bracket fasteners on the gearbox.
• Remove the support bracket (8).

Note: Mark the position of the exhaust flexible mount brackets on the body with a marker.

• Remove the mounting screw (9) of the exhaust line rubber mount bracket on the body.

• Remove the mounting screw (10) of the silencer rubber mount bracket on the body.
• Move the exhaust line rearward.

• Remove:

• the catalytic converter support bracket (11),
• the four mounting nuts (12) of the catalytic converter on the turbocharger,
• the catalytic converter

• Remove:

• the bracket (13),
• the heat shield of the EGR solenoid valve (14).

• Remove:

• the oil supply pipe (15),
• the oil return pipe (16),
• the two upper mounting nuts (17) of the turbocharger,
• the lower mounting nut from underneath,
• the turbocharger.

INSTALLATION

WARNING

• When refitting, make sure no foreign matter enters the turbine or the compressor.
• Check that the turbocharger oil return pipe is not partially or completely blocked by carbon deposits. Make sure it is not leaking; if so, replace it.
• Always replace:

• all O-rings and the two copper sealing washers of the turbocharger oil supply pipe,
• the exhaust flange gasket,
• any damaged heat shield.

• Refit in the reverse order of removal.
• Fit the catalytic converter.
• Hand-tighten the mounting bolts.
• Tighten to the following torques:

• the catalytic converter mounting nuts on the turbocharger (2.6 daN.m),
• the side stand mounting bolts (2.5 daN.m),
• the rear catalytic converter mounting bolts (2.1 daN.m).

• After a turbocharger failure, check that the air-to-air intercooler is not full of oil.

  If so, remove it, rinse it with cleaning product, then let it drain thoroughly.

• Apply LOCTITE FRENTANCH to the threads of the turbocharger oil supply pipe fitting on the cylinder head.
• Tighten to the following torques:

• the side stand mounting bolts on the engine (4.4 daN.m),
• the turbocharger mounting bolts on the exhaust manifold (2.6 daN.m),
• the EGR solenoid valve heat shield mounting bolts (1.2 daN.m),
• the turbocharger oil supply pipe fitting (2.3 daN.m),
• the turbocharger oil supply pipe fitting on the cylinder head (2.3 daN.m),
• the turbocharger oil return pipe on the turbocharger (1.2 daN.m),
• the turbocharger studs on the manifold (0.9 daN.m),
• the turbocharger studs on the turbocharger (0.9 daN.m).

WARNING

• Connect the battery; carry out the necessary re-learns (see Electrical Equipment chapter).
• Before starting, disconnect the flow actuator connector (do not start the engine).
• Crank the starter until the oil pressure warning light goes out (press for a few seconds).
• Switch off the ignition.
• Reconnect the flow actuator connector.
• Start the engine.
• Let the engine idle, then rev it several times without load.
• Switch off the ignition.
• Check for oil leaks.
• Connect the diagnostic tool and erase the stored faults.

• Check that all heat shields on the exhaust line are present and correctly secured.
• Check that there is no contact with the underbody.

F9Q

Essential equipment

Essential equipment

Tightening torques
turbocharger exhaust manifold nuts	2.6 +/- 0.2 daN.m
catalytic converter bracket nut, timing belt side	3 daN.m
catalytic converter bracket bolt, timing belt side	5 daN.m
catalytic converter bracket nuts, flywheel side	2.1 daN.m
catalytic converter bracket bolt, flywheel side	2.1 daN.m
exhaust line bracket mounting bolts	2.1 daN.m
torque rod bolt on the engine	18 daN.m
torque rod bolt on the subframe	10.5 daN.m
turbocharger mounting nuts	2.4 +/- 0.1 daN.m
oil supply fitting on the turbocharger	2.4 +/- 0.44 daN.m
oil supply fitting on the engine	2.6 +/- 0.2 daN.m
oil supply union bolt	1.2 +/- 0.1 daN.m

REMOVAL

• Position the vehicle on a two-post lift.
• Remove the engine covers.
• Disconnect the battery.

• Remove:

• the front right wheel,
• the engine undershield,
• the two nuts (1) of the exhaust flange.

Note: Mark the position of the exhaust flexible mount brackets on the body with a marker.

• Remove the mounting bolt (2) of the exhaust line rubber mount bracket from the body,

• Remove the mounting bolt (3) of the silencer rubber mount bracket.
• Move the exhaust line rearward.

• Remove:

• the mountings (4) of the catalytic converter bracket, flywheel side,
• the catalytic converter bracket, flywheel side,

• Remove:

• the mountings (5) of the catalytic converter bracket, timing belt side,
• the catalytic converter bracket, timing belt side.

• Remove the lower torque rod.
• Remove the engine lifting bracket.

• Remove:

• the three mounting nuts (6) of the catalytic converter on the turbocharger,
• the catalytic converter, from underneath the vehicle.

• Disconnect the air inlet and outlet pipes from the turbocharger.

• Disconnect the rubber hose (7) from the wastegate actuator.
• Remove:

• the turbocharger oil supply pipe (8),
• the turbocharger oil return pipe (9),
• the three turbocharger mounting nuts (10),
• the turbocharger.

INSTALLATION

WARNING

Special precautions:

• Before refitting, check that the turbocharger bearings are correctly lubricated.

  To do this:

• disconnect the high-pressure regulator connector,
• crank the starter (do not start the engine) (clear the ECU memory),

Oil must flow freely through the oil feed pipe (place a container underneath).

Otherwise, replace the lubrication pipe.

• When refitting, make sure no foreign matter enters the turbine or the compressor.
• After a turbocharger failure, check that the air-to-air intercooler is not full of oil. If so, remove it, rinse it with cleaning product, then let it drain.
• Check that the turbocharger oil return pipe is not partially or completely blocked by carbon deposits. Also check that it is fully sealed. Otherwise, replace it.

• Always replace:

• the copper sealing washer at the turbocharger oil supply union,
• the oil return pipe gasket,
• the catalytic converter gaskets with new gaskets,
• any damaged heat shield.

• Refit in the reverse order of removal.
• Refit the catalytic converter.
• Tighten the catalytic converter mounting nuts to the turbocharger to torque (2.6 +/- 0.2 daN.m).

• Refit the timing-side catalytic converter bracket, fitting the bolts by hand (do not tighten):

• the nut (11),
• the bolt (12).

• Tighten in sequence and to torque:

• the timing-side catalytic converter bracket mounting nut (3 daN.m),
• the timing-side catalytic converter bracket bolt (5 daN.m).

• Refit the flywheel-side catalytic converter bracket, fitting the bolts by hand (do not tighten):

• the bracket mounting nuts (13) and (14).
• the bracket mounting bolts (15),

• Tighten in the following order and to the following torques:

• the flywheel-side catalytic converter bracket mounting nuts (2.1 daN.m),
• the flywheel-side catalytic converter bracket bolts (2.1 daN.m).

• Tighten to torque:

• the exhaust line support mounting bolts (2.1 daN.m),
• the torque rod bolt on the engine (18 daN.m),
• the torque rod bolt on the subframe (10.5 daN.m),
• the turbocharger mounting nuts (2.4 +/- 0.1 daN.m),
• the oil supply union on the turbocharger (2.4 +/- 0.44 daN.m),
• the oil supply union on the engine (2.6 +/- 0.2 daN.m),
• the oil union bolts (1.2 +/- 0.1 daN.m).

• Check that all heat shields on the exhaust line are present and correctly secured.
• Refit the exhaust line, aligning it with the marks made previously.
• Check that there is no contact with the underbody.

WARNING

After each removal and refitting or replacement of the catalytic converter, carry out a road test (let the engine cycle the cooling fan on two starts).

WARNING

• Connect the battery; carry out the necessary re-learns (see Electrical Equipment chapter).
• Disconnect the flow actuator connector (do not start the engine).
• Crank the starter until the oil pressure warning light goes out (press for a few seconds).
• Switch off the ignition.
• Reconnect the flow actuator connector.
• Start the engine.
• Let the engine idle, then rev it several times without load.
• Switch off the ignition.
• Check for oil leaks.
• Connect the diagnostic tool and erase the stored faults.
• Check the boost pressure sensor and solenoid valve.