FITTING THE REPLACEMENT TURBOCHARGER

1 We had a selection of clearly labelled gaskets, nuts and a new oil feed pipe from Autovaux to fit to the replacement turbo. These were all bagged-up separately, making them easy to match to the old parts.

2 Before the turbo was fitted, we cleaned the mating surfaces for the oil drain pipe, intercooler and exhaust manifold. These are coated in the old gasket, so they needed to be cleaned to ensure a good seal.

3 Fitting the turbo and making sure the new gaskets didn’t fall off wasn’t easy. Some of the gaskets have foldable tabs, which can help to keep them in position, such as the intercooler gasket shown here.

4 Lowering the turbo into position proved to be awkward. On the part of the turbo that connects to the exhaust manifold, there are two studs that need to be fed through mounting holes on the exhaust manifold.

5 A new firing ring was carefully inserted between the turbine housing and the exhaust downpipe. It should only be fitted one way round, with the raised edge against the exhaust downpipe.

6 The oil drain pipe was reconnected, followed by the intercooler pipe, as shown here. The edges of the gasket and its locating tabs can be seen in the photograph.

7 Before the new oil feed pipe was fitted, we poured fresh engine oil into the top of the turbo to help prime it and ensure it didn’t run dry on the first start-up.

8 The new oil feed pipe was fitted between the top of the engine and the top of the turbo with new Torx T45 banjo bolts (notice the oil feed hole in the bolt for the engine side). All remaining parts were then refitted.