213019 Removing and installing turbocharger

WM 213019 Removing and installing turbocharger

Tools









Technical values






Preliminary work

DANGER

Vehicle can fall down

- Risk of squashing or crushing
- Risk of damage to the vehicle

-> Do not place any solid objects under the raised vehicle.
-> Ensure that the lifting platform is prevented from lowering.
-> Remove solid objects before lowering the vehicle.
-> Raise the vehicle only at the take-up points provided.
-> The outer take-up points should be used primarily.

Information

- It may only be supported over a large area at the oil pan.

- Localised loading is not permitted.

1. Remove rear apron.
=> 635519 Removing and installing rear apron.
2. Remove charge air cooler.
=> 214319 Removing and installing charge air cooler.

CAUTION

Hot components

- Risk of burns

-> Let hot components cool down.
-> Wear personal protective gear.

3. Remove heat shield on catalytic converter.
=> 635019 Removing and installing rear bumper.

Information

- When lowering, the engine must not rest on the rear axle cross member.

4. Lower the engine.
4.1. Support the engine at the oil pan with a transmission jack.
Transmission and unit jack Junior Jack 2.0 WE 1223 GA passenger car transmission plate WE 1224
4.2. Unscrew two M12 collar nuts (T55) -1- on the rear engine mountings from underneath.





Engine carrier on engine mounting

4.3. Slowly lower the engine using the transmission jack.
5. Remove catalytic converter.
=> 267319 Removing and installing catalytic converter - turbo engine.

Removing turbocharger

Removing turbocharger for cylinder bank 1-3

CAUTION

Hot components

- Risk of burns

-> Let hot components cool down.
-> Wear personal protective gear.

WARNING

Hot fluid

- Danger of scalding

-> Let the fluid cool down.
-> Wear personal protective gear.

WARNING

Caustic fluids

- Danger of chemical burns

-> Avoid contact with caustic fluid.
-> Wear personal protective gear.
-> Ensure that there is good ventilation.
-> If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.

Information

Specifications for wrench sizes (a/f specifications) for screw heads are described as follows:

- Torx screws: (E.) for external Torx, (T.) for internal Torx.

- Hexagon-head bolts (internal and external hexagon): Wrench size (a/f)

1. Unscrew external Torx screw (E10, M6 x 12) -1- on the holder for the turbocharger oil return line.
1.1. Unscrew external Torx screw (E10, M6 x 12) -2- on the oil return line at the turbocharger oil tank and pull the line out of the oil tank.
1.2. Collect emerging fluid and close off the opening using a suitable stopper.
1.3. Loosen M12 union nut (a/f 14) -3- on the exhaust temperature sensor and pull out the sensor.





Oil return line from oil tank to turbocharger (view of cylinder bank 4-6)

2. Pull off rubber cap over the cable plug for the electronic adjuster -arrow- , then release and pull off the cable plug.





Cable plug for electronic adjuster on cylinder bank 1-3

3. Unscrew two external Torx screws (E10, M6 x 30) -2- for the intake air line on the turbocharger.
3.1. Remove the cover -1- on the electronic adjuster and pull the intake air line out of the turbocharger.
3.2. Replace O-ring on intake air line.





Electronic adjuster cover, cylinder bank 1-3

4. Unscrew external Torx screw (E10, M6 x 12) -1- on the vent line holder.





Holder for turbocharger for cylinder bank 1-3

NOTICE

Mixing fluids

- Risk of damage to components

-> Close off all openings immediately after exposing them (with adhesive tape, suitable stoppers).

5. Unscrew external Torx screw (E10, M6 x 12) -1- on the vent line and pull the line out of the oil tank.
Collect emerging fluid and close off the opening using a suitable stopper.





Oil tank vent line and turbocharger coolant line

6. Unscrew external Torx screw (E10, M6 x 12) -1- on the coolant line holder.





Cable plug for electronic adjuster on cylinder bank 1-3

7. Loosen internal Torx screw (T30, M6 x 12) -2- on the bottom coolant line and pull the line out of the turbocharger.
Collect emerging fluid and close off the opening using a suitable stopper.





Oil tank vent line and turbocharger coolant line

8. Remove coolant line and oil pressure line at the turbocharger.
8.1. Unscrew internal Torx screws (T30, M6 x 12) on the top coolant line -1- and oil pressure line -2- at the turbocharger.
8.2. Then pull both lines out of the turbocharger.
8.3. Collect emerging fluid and close off the openings using suitable stoppers.





Coolant line and oil pressure line on turbocharger

9. Unscrew three M8 collar nuts (a/f 12) -arrows- on the exhaust manifold flange.
9.1. Replace collar nuts.





Exhaust manifold flange on cylinder bank 1-3

10. Unscrew external Torx screw (E12, M8 x 16) -2- on the turbocharger holder.
Get another person to help to support the turbocharger.





Holder for turbocharger for cylinder bank 1-3

11. Pull the turbocharger up off the threaded bolts on the exhaust manifold flange and remove it.
12. Clean sealing faces on the turbocharger and exhaust manifold.
12.1. Clean studs (M8) with a wire brush and replace them if necessary.
12.2. Replace exhaust manifold flange seal.

Removing turbocharger for cylinder bank 4-6

CAUTION

Hot components

- Risk of burns

-> Let hot components cool down.
-> Wear personal protective gear.

WARNING

Hot fluid

- Danger of scalding

-> Let the fluid cool down.
-> Wear personal protective gear.

WARNING

Caustic fluids

- Danger of chemical burns

-> Avoid contact with caustic fluid.
-> Wear personal protective gear.
-> Ensure that there is good ventilation.
-> If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.

NOTICE

Mixing fluids

- Risk of damage to components

-> Close off all openings immediately after exposing them (with adhesive tape, suitable stoppers).

Information

Specifications for wrench sizes (a/f specifications) for screw heads are described as follows:

- Torx screws: (E.) for external Torx, (T.) for internal Torx.

- Hexagon-head bolts (internal and external hexagon): Wrench size (a/f)

1. Unscrew external Torx screw (E10, M6 x 12) -1- on the holder for the turbocharger oil return line.
1.1. Unscrew external Torx screw (E10, M6 x 12) -2- on the oil return line at the turbocharger oil tank and pull the line out of the oil tank.
1.2. Collect emerging fluid and close off the opening using a suitable stopper.
1.3. Loosen M12 union nut (a/f 14) -3- on the exhaust temperature sensor and pull out the sensor.





Oil return line from oil tank to turbocharger (view of cylinder bank 4-6)

2. Release and pull off cable plug -1- on electronic adjuster.





Turbocharger holder

3. Unscrew external Torx screws (E10, M6 x 20) -1- for the intake air line on the turbocharger.
3.1. Pull intake air line out of the turbocharger -horizontal arrow-. Replace O-ring.
3.2. Press intake air line up out of the rubber mounting in the engine compartment -vertical arrow-.





Intake air line on cylinder bank 4-6

4. Remove connecting lines on the turbocharger and loosen fastening points for the lines.
4.1. Unscrew external Torx screws (E10, M6 x 12) on the holder for the vent line -3- and coolant lines -4-.
4.2. Unscrew external Torx screw (E10, M6 x 12) -1- on the vent line at the turbocharger oil tank and pull the line out of the oil tank.
4.3. Loosen internal Torx screw (T30, M6 x 12) -2- on the bottom coolant line and pull the line out of the turbocharger.
4.4. Collect emerging fluid and close off the openings using suitable stoppers.





Holder for coolant line and vent line

5. Unscrew external Torx screw (E10, M6 x 12) -1- on the oil pressure line holder.





Oil pressure line holder on turbocharger

6. Unscrew internal Torx screws (T30, M6 x 12) on the top coolant line -2- and oil pressure line -1- at the turbocharger and pull off the lines.





Coolant line and oil pressure line on turbocharger

7. Replace all O-rings.
8. Unscrew three M8 collar nuts (a/f 12) on the exhaust manifold flange -arrows-.
8.1. Replace collar nuts.





Exhaust manifold flange on cylinder bank 4-6

9. Unscrew external Torx screw (E12, M8 x 16) -2- on the turbocharger holder.
Get another person to help to support the turbocharger.





Turbocharger holder

10. Pull the turbocharger outwards off the studs on the exhaust manifold flange and remove it.
11. Clean sealing faces on the turbocharger and exhaust manifold.
11.1. Clean studs (M8) with a wire brush and replace them if necessary.
11.2. Replace exhaust manifold flange seal.

Installing turbocharger

Installing turbocharger for cylinder bank 1-3

Information

Specifications for wrench sizes (a/f specifications) for screw heads are described as follows:

- Torx screws: (E.) for external Torx, (T.) for internal Torx.

- Hexagon-head bolts (internal and external hexagon): Wrench size (a/f)

1. Pull off stoppers on oil and coolant lines one after the other, collect residual fluid and then re-insert the stoppers. Do not remove the stoppers again until immediately before fitting each line.
2. Fit exhaust manifold seal and slide the turbocharger onto the studs on the exhaust manifold.
Always replace the metal seal on the exhaust manifold.

Information

- Replace O-rings.

- Grease O-rings with a light coating of Kluber Syntheso Glep (Part No.: 000.043.204.68).

3. Fit new O-rings on all connecting lines and grease with the prescribed lubricant.
4. Fit oil pressure line on the turbocharger and fit and tighten the internal Torx screw (T30, M6 x 12).
=> Tightening torque: 10 Nm (7.5 ftlb.)
5. Fit upper coolant line on the turbocharger and fit and tighten the internal Torx screw (T30, M6 x 12).
=> Tightening torque: 10 Nm (7.5 ftlb.)
6. Fit lower coolant line on the turbocharger and fit and tighten the internal Torx screw (T30, M6 x 12).
=> Tightening torque: 10 Nm (7.5 ftlb.)
7. Fit vent line on the oil tank and fit and tighten the external Torx screw (E10, M6 x 12).
=> Tightening torque: 10 Nm (7.5 ftlb.)
8. Fit and tighten external Torx screw (E12, M8 x 16) on the turbocharger holder.
=> Tightening torque: 23 Nm (17 ftlb.)
9. Fit and tighten external Torx screw (E10, M6 x 12) on the vent line holder.
=> Tightening torque: 10 Nm (7.5 ftlb.)
10. Fit oil return line on the oil tank and fit and tighten external Torx screw (E10, M6 x 12).
10.1. Fit and tighten external Torx screw (E10, M6 x 12) on the oil return line holder.
10.2. => Tightening torque: 10 Nm (7.5 ftlb.)

NOTICE

Exhaust emissions temperature sensor fitted incorrectly

- Risk of damage to components

-> Only use prescribed lubricant when installing the sensor.
-> Carefully check the thread for damage and smear the surface with Optimol MF Paste (Part No. 000.043.207.07).

11. Fit exhaust temperature sensor.
11.1. Grease thread with the prescribed lubricant.
11.2. Fit sensor on the turbocharger and fit and tighten M12 union nut (a/f 14) on the exhaust temperature sensor.
=> Tightening torque: 35 Nm (26 ftlb.)+/-3 Nm (+/-2 ftlb.)
12. Fit and tighten new M8 collar nuts (a/f 12) on the exhaust manifold flange.
=> Tightening torque: 25 Nm (19 ftlb.)
13. Fit intake air line with cover on the turbocharger. Grease O-ring with the prescribed lubricant.
13.1. Fit new O-ring on the intake air line.
13.2. Fit cover on electronic adjuster and secure the intake air line and cover with two fastening screws (E10, M6 x 30).
13.3. Tighten the screws.
=> Tightening torque: 10 Nm (7.5 ftlb.)
14. Connect cable plug on the electronic adjuster.

Installing turbocharger for cylinder bank 4-6

Information

Specifications for wrench sizes (a/f specifications) for screw heads are described as follows:

- Torx screws: (E.) for external Torx, (T.) for internal Torx.

- Hexagon-head bolts (internal and external hexagon): Wrench size (a/f)

1. Pull off stoppers on oil and coolant lines one after the other, collect residual fluid and then re-insert the stoppers.
1.1. Do not remove the stoppers again until immediately before fitting each line.
2. Fit new flange gasket on the exhaust manifold and slide the turbocharger onto the studs on the exhaust manifold.
Always replace the metal seal on the exhaust manifold.

Information

- Replace O-rings.

- Grease O-rings with a light coating of Kluber Syntheso Glep (Part No.: 000.043.204.68).

Fit new O-rings on all connecting lines and grease with the prescribed lubricant.
3. All tightening torque values are the same as specified in the installation description for cylinder bank 1-3!
4. Fit oil pressure line on the turbocharger and fit and tighten the internal Torx screw (T30, M6 x 12).
5. Fit upper coolant line on the turbocharger and fit and tighten the internal Torx screw (T30, M6 x 12).
6. Fit lower coolant line on the turbocharger and fit and tighten the internal Torx screw (T30, M6 x 12).
7. Fit vent line on the oil tank and fit and tighten the external Torx screw (E10, M6 x 12).
8. Fit and tighten external Torx screw (E12, M8 x 16) on the turbocharger holder.
9. Fit and tighten external Torx screw (E10, M6 x 12) on the holders for the vent line and coolant lines.
10. Fit oil return line on the oil tank and fit and tighten external Torx screw (E10, M6 x 12).
10.1. Fit and tighten external Torx screw (E10, M6 x 12) on the oil return line holder.

NOTICE

Exhaust emissions temperature sensor fitted incorrectly

- Risk of damage to components

-> Only use prescribed lubricant when installing the sensor.
-> Carefully check the thread for damage and smear the surface with Optimol MF Paste (Part No. 000.043.207.07).

11. Fit exhaust temperature sensor.
11.1. Grease thread with the prescribed lubricant.
11.2. Fit sensor on the turbocharger and fit and tighten M12 union nut (a/f 14) on the exhaust temperature sensor to the specified torque.
12. Fit new M8 collar nuts on the exhaust manifold flange and tighten to the specified torque.
13. Fit intake air line with cover on the turbocharger. Grease new O-ring with the prescribed lubricant.
13.1. Fit intake air line on the turbocharger.
13.2. Fit cover on electronic adjuster and secure the intake air line and cover with two fastening screws (E10, M6 x 20).
13.3. Tighten screws to the specified torque.
=> Tightening torque: 10 Nm (7.5 ftlb.)
14. Connect cable plug on the electronic adjuster.

Subsequent work

1. Install catalytic converter.
=> 267319 Removing and installing catalytic converter - turbo engine.

WARNING

Objects or loads falling down

- Risk of squashing or crushing

-> Secure components to prevent them from falling down.

Information

- It may only be supported over a large area at the oil pan.

- Localised loading is not permitted.

2. Secure the engine.
2.1. Raise the engine using a transmission jack and move it into installation position.
2.2. Fit and tighten two M12 collar nuts (internal Torx T55) on the rear engine mountings.
=> Tightening torque: 85 Nm (63 ftlb.)
2.3. Slowly lower the transmission jack and remove it from the work area.
3. Install heat shield on catalytic converter.
=> 635019 Removing and installing rear bumper.
4. Install charge air cooler.
=> 214319 Removing and installing charge air cooler.
5. Install rear silencer.
=> 263319 Removing and installing rear silencer - Turbo.
6. Install rear apron.
=> 635519 Removing and installing rear apron.