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Turbocharger, Replace (Z 17 DTH, With Air Conditioning, LHD) > < Charge Pressure Sensor, Replace (Z 17 DTH, With Air Conditioning, LHD)

Corsa C

Turbocharger, Replace

  Remove

1.   Open bonnet
Important:   On vehicles as of model year 04 with ESP - every time the battery is disconnected, the steering angle sensor loses its basic setting. It must be recalibrated.
2.   Disconnect battery
3.   Drain coolant
•   Place collecting basin underneath.
•   Open drain bolt
Object Number: 2411059 Size: DEFAULT


4.   Remove charge air pipe (1)
•   Release 2x clamp
•   Unscrew 2x bolt (arrows)
•   Unclip wiring harness
•   Detach hose
Object Number: 2406298 Size: DEFAULT


5.   Detach oil filter housing heat shield
•   Unscrew nut
•   Unscrew 2 bolts
6.   Detach exhaust manifold heat shield (2)
•   Disconnect oil pressure switch wiring harness plug
•   Unscrew 3 nuts
•   Remove engine transport shackle
7.   Detach turbocharger charge air pipe (3)
•   Release clamp
•   Open quick-release fitting
8.   Loosen heat exchanger coolant pipe (1)
•   Close coolant drain bolt
•   Place collecting basin underneath.
•   Unscrew 3 bolts
•   Release clamp
9.   Remove oil feed line (4)
•   Place collecting basin underneath.
•   Unscrew 2 banjo bolts
Object Number: 2406310 Size: DEFAULT


10.   Remove oil filter housing/heat exchanger housing (1)
•   Disconnect lower radiator hose
– Release clamp
•   Unscrew 4 bolts
Object Number: 2406311 Size: DEFAULT


11.   Loosen catalytic converter (1)
•   From turbocharger
•   Open retaining plate (2)
•   Unscrew 3 bolts
Object Number: 2406312 Size: DEFAULT


12.   Raise vehicle
Important:   When removing the centre muffler, a catalytic converter, an exhaust manifold, or an exhaust manifold with catalytic converter, secure that portion of the exhaust system remaining on the vehicle against uncontrolled suspension. The exhaust system piece with the flex pipe inside can be secured for this purpose using suitable means, such as a wire on the vehicle underbody. Bends in the flex pipe with an angle as little as 5 – 10 degrees from the intended installation position may result in damage with subsequent total failure of the flex pipe.
13.   Remove exhaust system
Note:   On Z 13 DT
•   Release clamp
14.   Attach exhaust system to underbody at the side
Note:   On Z 13 DT
•   Detach exhaust system
Note:   2nd mechanic required.
– Detach 5 damper rings
•   Attach exhaust system
15.   Release front exhaust pipe from particulate filter
Note:   For Z 13 DTJ engine
•   Detach 2x damping rings
– Unscrew 2 nuts
•   Unscrew 3 nuts
•   Detach line, differential pressure sensor
– Remove nut
16.   Disconnect catalytic converter
•   Unscrew bolt, bracket
•   Remove catalytic converter downwards
17.   Release turbocharger oil return line
•   Unscrew 2 bolts (3)
– At cylinder block
18.   Lower vehicle
19.   Remove turbocharger (2)
•   Unscrew 3x nut (1)
Object Number: 2408390 Size: DEFAULT


20.   Detach turbocharger oil return line
•   From turbocharger
•   Unscrew 2 bolts
21.   Cleaning work
•   On cylinder block, catalytic converter

  Install

22.   Attach turbocharger oil return line
•   To turbocharger
•   Replace gasket
•   Tighten 2 bolts 9 Nm
23.   Install turbocharger
•   Tighten 3 new nuts 25 Nm
24.   Raise vehicle
25.   Attach turbocharger oil return line
•   Tighten 2 bolts 9 Nm
– At cylinder block
26.   Fasten catalytic converter
Note:   On Z 13 DT
•   Tighten bolt 25 Nm
27.   Attach catalytic converter with front exhaust pipe
Note:   On Z 13 DTJ
•   Attach catalytic converter bracket
– Tighten bolt
•   Tighten 3x nut, particulate filter flange 45 Nm
•   Insert 2x damper rings
•   Attach pipe, differential pressure sensor
– Tighten nut 45 Nm
•   Attach temperature sensor
– Tighten nut 45 Nm
28.   Attach exhaust system
Note:   On Z 13 DT
•   Fasten clamp 35 Nm
29.   Lower vehicle
30.   Attach catalytic converter
•   To turbocharger
•   Replace gasket, retaining plate
•   Tighten 3x bolts 30 Nm
•   Fasten 3 bolts
31.   Cleaning work
•   At cylinder block
32.   Install oil filter housing/heat exchanger
•   Replace gasket
•   Tighten 4 bolts 9 Nm
•   Connect lower radiator hose
– Fasten clamp
33.   Install turbocharger oil feed line
•   Replace 4x seal ring
•   Tighten 2 banjo bolts 12 Nm
34.   Attach heat exchanger coolant pipe
•   Replace gasket
•   Tighten 3 bolts 9 Nm
35.   Attach exhaust manifold heat shield
•   Position engine transport shackle
•   Replace 3x nut
•   Tighten 3 new nuts 9 Nm
•   Connect wiring harness plug of oil pressure switch
36.   Attach oil filter housing heat shield
•   Tighten nuts
•   Tighten 2 bolts
37.   Install charge air pipe
•   Attach 2 clamps 3.5 Nm
•   Tighten 2 bolts
•   Attach wiring harness
•   Attach hose
38.   Attach turbocharger charge air hose
•   Fasten clamp 3.5 Nm
•   Close quick-release fitting
39.   Connect battery
40.   Top up coolant
41.   Check engine oil level, if necessary correct.
•   Observe specified engine oil quantity
42.   Program volatile memory
43.   Close bonnet

Turbocharger, Replace (Z 17 DTH, With Air Conditioning, LHD) > < Charge Pressure Sensor, Replace (Z 17 DTH, With Air Conditioning, LHD)