Turbocharger, Removing and Installing

Turbocharger, Removing And Installing

Removing

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

- Remove engine cover (complete).







- Remove sound insulation (arrows).
- Unbolt heat shield for right drive axle.
- Remove right drive axle.
- Remove front exhaust pipe.

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

- Drain cooling system.
- Drain engine oil.







- Remove air hose -1- between upper air line and lower air line.
- Unbolt bracket -2- for upper air line.
- Remove oil return line -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 line (bolt -4-).
- Unbolt coolant supply line from cylinder block (bolt -5-).
- Disconnect hose from pressure unit for charge air pressure control valve (on turbocharger).







Air intake hose is removed from connection on turbocharger as follows:
- Remove pressure control valve -8- (for crankcase breather) from hose.
- Disconnect connector -6- from Wastegate bypass regulator valve -N75-.
- Disconnect hose -2- from upper air line (hose leads to -N75-).
- Disconnect hose -5- from Wastegate bypass regulator valve -N75-.
- Disconnect hose -1- from air line.
- Disconnect vacuum line -4- from recirculating valve for turbocharger.
- 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 Y connection on right next to cylinder head (hose leads to turbocharger).







- Disconnect hose -3- from upper air line (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 line.
- Remove upper air line and heat shield.







- Unbolt turbocharger -1- from exhaust manifold -2-.
- Remove gasket. 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 line from turbocharger (arrow).
- Bolt turbocharger bracket back onto cylinder block.







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

Installing

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

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







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

- Install coolant return line -1- with spacer sleeve and bolt it to 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 performed in the reverse sequence. Note the following points:
- Install heat shield sleeves on hoses around turbocharger.
- Fill with coolant.
- Fill with engine oil.

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

Tightening torques

Components Nm
Oil return line to oil pan 10 Nm
Oil return line to turbocharger 10 Nm
Coolant supply line to cylinder block 35 Nm
Turbocharger bracket to turbocharger 30 Nm
Turbocharger bracket to cylinder block 25 Nm
Oil supply line to turbocharger 30 Nm
Oil supply line retainer piece to
turbocharger 10 Nm
Coolant return line to turbocharger 35 Nm
Turbocharger to exhaust manifold 30 Nm
Exhaust manifold to cylinder head 25 Nm
Front exhaust pipe to turbocharger 40 Nm
Drive axle heat shield to cylinder
block 35 Nm
Nuts for clamp 40 Nm