Turbocharger, Assembly Overview
Part I
Notes: Replace all gaskets and seals.
1 - Front exhaust pipe
2 - 40 Nm
^ Replace
3 - Spacer sleeve
4 - Gasket
^ Replace
5 - 10 Nm
^ Install with locking fluid D 000 600 A2
6 - Pressure Unit
^ For charge pressure regulating valve
7 - Securing clip
8 -5Turbocharger
9 - O - ring
^ Replace
10 - 10 Nm
11 - Connection
12 - Gasket
^ Replace
^ Note installation position
13 - 20 Nm
14 - Heat shield
^ Charge air system with turbocharger
15 - 10 Nm
16 - Banjo bolt - 30 Nm
17 - Oil supply pipe
18 - 30 Nm
^ Replace
^ Coat threads and bolt head seating surface with G000500
19 - Exhaust manifold
20 - Gasket
^ Replace
^ Note installation position
21 - 20 Nm
22 - Banjo bolt - 30 Nm
23 - 25 Nm
^ Replace
24 - Banjo bolt - 35 Nm
25 - Coolant return pipe
26 - 25 Nm
27 - Spacer sleeve
28 - Banjo bolt - 35 Nm
29 - 10 Nm
30 - Coolant supply hose/pipe
31 - Banjo bolt - 35 Nm
32 - Bracket
33 - 30 Nm
^ Use only genuine bolts
^ Refer to parts supplier
34 - 25 Nm
35 - Gasket
^ Replace
36 - Gasket
^ Replace
37 - 10 Nm
38 - Oil return pipe
^ To sump
39 - 10 Nm
40 - 10 Nm
^ Install with locking fluid D 000 600 A2
Part II
1 - To charge pressure control valve
2 - Locking clip
3 - O - ring
^ Replace
4 - Air intake hose
^ To connection on turbocharger
5 - Solenoid valve for boost pressure control - N75
6 - Mechanical air recirculation valve
7 - Hose
^ To air recirculation valve for turbocharger - N249
8 - Pressure regulating valve
^ For crankcase breather
9 - Hose
^ Between mechanical air recirculation valve and upper air pipe
10 - To crankcase breather
11 - Upper air pipe
12 - 25 Nm
13 - 25 Nm
14 - To throttle valve housing
15 - Non - return valve
^ Install with light and dark sides in the positions shown in the illustration 16 - To solenoid valve 1 for activated charcoal filter - N80
17 - Hose
18 - Non - return valve
^ Install with light and dark sides in the positions shown in the illustration 19 - Coolant pipe
20 - To connection on turbocharger
21 - To pressure unit for charge pressure control valve