TURBO REPLACEMENT INSTRUCTIONS

[93 98-03, 900 94-98]

STEP 1 Loosen the coolant drain Plug and remove the coolant. Loosen the lid on the expansion tank to speed up the draining. STEP 2 Remove the air pipe and the hose between the turbocharger and the charge air cooler. This may be easier with the car up in the air. STEP 3 Undo the joint between Header pipe and the intermediate pipe and Loosen the screw which holds the exhaust pipe to the engine bracket. STEP 4 Remove the header pipe from the turbocharger and position the pipe so that the O2 sensor's cable is not stretched. STEP 5 Remove the locking ring on the waste gate. STEP 6 Remove the bracket on the turbocharger and remove the oil return pipe. Cover the pipe with a rag so that nothing falls in it. STEP 7 Undo the oil filter pipe. STEP 8 Remove the hoses to the boost pressure control valve. Be careful to mark the position where the hoses are. You can wrap tape around each fitting and mark them #1, #2, etc.. STEP 9 Remove the intake hose & bypass hose, Loosen the waste gate's diaphragm unit and remove the intake pipe along with the crankcase ventilation pipe. STEP 10 Remove the oil supply pipe to the turbocharger & remove the lower coolant pipe. STEP 11 Remove the screws for the upper coolant pipe from the turbocharger. STEP 12 Remove the turbocharger. STEP 13 INSTALLATION OF THE TURBO STEP 14 Clean the sealing surfaces and fit the New turbocharger & tighten the bolts to 16 ft lb of torque. Be sure to fill the oiling section of the turbo with engine oil. It is Very important for oil to be present in the turbocharger when the engine is started or you will cause damage to the new Turbocharger. STEP 15 Refit the coolant pipes and the oil pipe to the turbocharger. STEP 16 Install intake pipe together with the crank ventilation pipe. Tighten the nuts on the waste gate's diaphragm unit and connect the hoses from the boost pressure control valve (you should have previously marked their position). STEP 17 Refit the intake hose & bypass hose. At this point you may want to raise the car or jack up the car. STEP 18 Connect the oil pipe to the oil filter first and then refit the oil return pipe. STEP 19 Install the waste gate lock ring and refit the bracket between the turbocharger and the block. STEP 20 Refit the header pipe to the turbocharger (you may want to coat the header pipe to turbo bolts with some type of molycoat here). Reinstall the header to intermediate pipe clamps and secure the bracket bolt that connects the header pipe to the engine. STEP 21 Install the pipe and the hose between the turbocharger and the Intercooler. STEP 22 Tighten the radiator drain plug. Fill with coolant & check for leaks. STEP 23 Check the oil level. STEP 24 Re-seal the pressure rod. STEP 25 Make sure that the boost pressure is set correctly. (check the length of the waste gate rod on the original turbocharger and compare the two) In most cases the boost pressure will be close. The correct way to adjust it is to adjust base boost. STEP 26 Adjust the basic boost pressure by turning the waste gate end piece in if the basic boost pressure is too low and by turning it out if it is too high. One full turn of the end piece results in a change in the basic boost pressure of about 0.02 bar. (you turn the rod in or out with a pair of pliers. Keep the pliers as close to the threads as possible to avoid damaging the rod close to the diaphragm)