Turbocharger, Removing and Installing

Removing

Notes: The turbocharger is removed from below after taking out the exhaust manifold.

^ Remove engine cover (complete).





^ Remove noise insulation - arrows -.
^ Unbolt heat shield for right drive axle.
^ Remove right drive axle.
^ Remove front exhaust pipe.

Notes: Do not bend the flexible connection (de - coupling element) in the exhaust system more than 10° , otherwise it may be damaged.

^ Drain cooling system.
^ Drain engine oil.





^ Remove air hose - 1 - between upper air pipe and lower air pipe.
^ Unbolt bracket - 2 - for upper air pipe.
^ Remove oil return pipe - 3 - .





^ Loosen bolted connection - 3 - for turbocharger bracket by a few turns.
^ Remove turbocharger bracket from cylinder block (bolts - 1 - and - 2 -).
^ Unbolt bracket for coolant return pipe (bolt - 4 -).
^ Unbolt coolant supply pipe from cylinder block (bolt - 5 -).
^ Disconnect hose from pressure unit for charge pressure control valve (on turbocharger).





Air intake hose is detached from connection on turbocharger as follows:
^ Detach pressure control valve - 8 - (for crankcase breather) from hose.
^ Unplug connector- 6 - from charge pressure control valve - N75.
^ Disconnect hose - 2 - from upper air pipe (hose leads to charge pressure control valve- N75).
^ Disconnect hose - 5 - from charge pressure control valve - N75.
^ Disconnect hose - 1 - from air pipe.
^ Disconnect vacuum pipe - 4 - from air recirculation valve.
^ Disconnect air intake hose - 7 - from air cleaner.
^ Pull locking clip out of turbocharger connection and take off air intake hose.
^ Disconnect hose - 3 - from non - return valve (hose leads to turbocharger).
^ Disconnect coolant return hose from the Y connection on the right next to the cylinder head (hose leads to turbocharger).





^ Disconnect hose - 3 - from upper air pipe (hose leads to turbocharger).
^ Remove bolts - 1 - and - 4 - for heat shield on back of cylinder head.
^ Remove bolts - 2 - and - 5 - on upper air pipe.
^ Remove upper air pipe and heat shield.





^ Unbolt turbocharger - 1 - from exhaust manifold - 2 -.
^ Remove gasket. The turbocharger will drop down slightly.
^ Remove all nuts - arrows - on exhaust manifold (nuts can be reached from above).
^ Remove washers and take off exhaust manifold.





^ Unbolt retainer piece for oil supply pipe from turbocharger (arrow).
^ Bolt turbocharger bracket back onto cylinder block.





^ Unbolt oil supply pipe (bolt - 2 -) and coolant return pipe (bolt - 1 -) from turbocharger.
^ Remove spacer sleeve from connection for coolant return pipe.
^ Disconnect coolant return pipe.
^ Unbolt turbocharger bracket from cylinder block and remove turbocharger.

Installing

Notes: Fill the turbocharger with engine oil via the oil supply connection.

^ Bolt turbocharger bracket onto turbocharger but do not tighten the bolts.
^ Position turbocharger against engine from below, then tighten bolts by hand to secure bracket to cylinder block.





^ Tighten bolts for oil supply pipe - 2 -.
- Banjo bolt: 30 Nm
- Bolt for retainer piece: 10 Nm

^ Install coolant return pipe - 1 - with spacer sleeve and bolt it to the turbocharger (35 Nm).
^ Unbolt turbocharger bracket from cylinder block again.
^ Install exhaust manifold (25 Nm).
^ Bolt turbocharger to exhaust manifold.

The remaining installation steps are carried out in the reverse sequence, noting the points:
^ Fit heat shield sleeves on hoses around turbocharger.
^ Fill up with coolant.
^ Fill up with engine oil.

Notes: After installing the turbocharger, run the engine for approximately 1 minute at idling speed; do not rev. up immediately. This ensures that the turbocharger is properly lubricated.





Tightening torques