Turbocharger: Service and Repair

REMOVAL AND INSTALLATION OF EXHAUST GAS TURBOCHARGER

Turbocharger designation



Garret TA 0301
Kuhnle Kopp and Kausch KKK 532 679 60 31


Removal




1. Remove air filter, detaching air filter cover and unscrewing 3 fastening nuts.

2. On vehicles with automatic climate control or air-conditioning remove electric line for 100°C temperature switch (1).




3. Release lower hose clip (arrow) on intake line (4) from air filter to compressor housing. On vehicles up to model 1979 only.

4. Remove vacuum line (2) and crankcase ventilation pipe (3).

5. Remove air filter with intake line (4).




6. Unscrew engine oil supply line (1).

7. Unscrew air filter holder (2). To do so, release 3 hex-head bolts (2 from above, 1 from below) and remove holder.




8. Unscrew exhaust flange (arrow).

9. Release and remove exhaust holder on automatic transmission.

10. Force exhaust pipe toward rear.




11. Unscrew holder (1) for adapter fitting (2).

12. Unscrew 4 fastening nuts (arrows) at exhaust driven turbocharger and remove turbocharger.

13. Unscrew adapter fitting (2) at exhaust-driven turbocharger (3).




14. Unscrew oil return pipe (92) at turbocharger.


Installation

Install in reverse order, using new gaskets (repair set). Please note the following points:

15. Prior to installing turbocharger, attach adapter fitting and oil return pipe. Correct positioning is absolutely essential.




16. Insert flange gasket between turbocharger and exhaust manifold so that bead (arrow) is at exhaust manifold side.

17. Always use heat resistant nuts and bolts to attach the turbocharger.




18. Prior to using a replacement turbocharger, fill with approx. 1/8 l engine oil through engine oil supply hole (arrow).




19. Make sure that intake line (4) is fitted in such a way that rubber sealing rings are correctly positioned.