Removal and Replacement
Turbocharger, Removing and Installing
Special tools and equipment
^ Hose clamps 3094
Removing
^ Remove sound insulation -arrows-.
^ Loosen bolts securing ribbed belt tensioning roller for A/C compressor arrows-. Loosen belt and remove.
CAUTION! The air conditioner refrigerant circuit must not be opened.
^ Disconnect A/C compressor from bracket and secure to body with wire.
^ Remove bracket for exhaust turbocharger -2-.
^ Unscrew oil return pipe -1- from exhaust turbocharger and set aside.
^ Loosen air duct hoses -4- and -5- on exhaust turbocharger.
^ Remove banjo bolt -3- for pressure line.
^ Remove engine cover -arrows-.
^ Remove air filter cover -arrow-.
^ Remove bolts -arrows,
^ Remove air duct -1- and -2-.
^ Disconnect wiring connectors as follows:
1 - on ACF valve (in addition, remove ACF valve from air filter housing)
2 - on mass air flow sensor
3 - on Wastegate Bypass Regulator valve -N75-
^ Move wiring aside and remove air filter housing -arrows-.
^ Remove secondary air inlet pipe by disconnecting hoses -arrows- and removing bolts -1-.
^ Remove right-hand heat shield on cylinder head.
^ Remove hose of vacuum unit for wastegate bypass regulator valve on exhaust turbocharger.
^ Unbutton sleeve on coolant return hose.
^ Clamp coolant return hose to exhaust turbocharger with hose clamp 3094.
^ Loosen hose clamp -4- and remove coolant return hose from exhaust turbocharger line.
^ Loosen bolts -1- and -3- of oil feed pipe.
^ Remove oil feed pipe -5- at exhaust turbocharger.
Note: The isolating element in the exhaust system must not be bent more than 10 or it may be damaged.
^ Remove catalytic converter from exhaust turbocharger -6-.
^ Remove exhaust turbocharger from exhaust manifold -2-.
^ Swivel exhaust turbocharger to side, loosen mounting angle and banjo bolt of coolant feed line on exhaust turbocharger.
^ Remove exhaust turbocharger.
Installing
Installation is carried out in the reverse order of removal.
Note:
^ All cable ties which are released or cut open when removing must be installed in the same position when installing.
^ Secure all hose connections with the correct hose clips (same as original equipment):
Refer to, Parts supplier
^ The hose connectors and hoses must be free of oil and grease before assembling.
^ Always replace seals, gaskets and self-locking nuts.
^ Perform the operating steps before tightening exhaust turbocharger:
- Fasten coolant feed line loosely to bracket on vacuum unit for wastegate bypass regulator valve.
- Tighten banjo bolt to 35 Nm and then tighten securing bolt of bracket to 10 Nm.
Note: Fill the exhaust turbocharger with engine oil via the oil supply connection.
^ Install ribbed belt for A/C compressor.
^ Top up coolant.
^ Check oil level.
Note: After installing the turbocharger, run engine for approximately 1 minute at idling speed; do not rev up immediately. This ensures the turbocharger is properly lubricated.
Tightening Torques (Part 1 Of 3):
Tightening Torques (Part 2 Of 3):
Tightening Torques (Part 3 Of 3):
Tightening torques
1) Replace bolts
2) Coat thread and head attachment area with high temperature lubricant G 052 112 A3