Turbocharger: Service and Repair

WM 213019 Removing and installing turbocharger

Preliminary work

Preliminary work for removing and installing turbocharger

1. Remove engine. -> 100119 Removing and installing engine - section on "Removing" 100119 Removing and installing engine
2. Remove primary catalytic converters. -> 267619 Removing and installing primary catalytic converter - section on "Removing" 267619 Removing and installing primary catalytic converter
3. Drain engine oil. -> 170117 Changing engine oil and oil filter Removal and Replacement

Removing turbocharger

Removing turbocharger, cylinder bank 1 - 4

Information

- The turbocharger is removed from the engine with all lines fitted. To do this, detach the lines at the connection points on the engine side and remove the turbocharger. Only disconnect the lines on the turbocharger if they are damaged or if the turbocharger has to be replaced.

- When removing the turbocharger take note of the connection points for the lines.

- If the lines that are screwed to the turbocharger need to be disconnected, their position must be marked before disconnecting them. During reinstallation, the lines must be tension-free and must not be bent.

Information

- The pictures shown in this document may differ from the original.

- However, this does not affect the validity and relevance of the pictures.

Turbocharger, cylinders 1 - 4

NOTICE

Sheared-off sealing grommet on turbocharger intake pipe

- Risk of damage to turbocharger

-> A previously used intake pipe must not be re-used
-> Replace intake pipe and sealing grommet
-> Replace hose clamp
-> Coat area around sealing grommet on new intake pipe with water during fitting

1. Loosen screw-type clamp -2- for the intake pipe -1- on the turbocharger.

Intake pipe on turbocharger

2. Pull hose line off the bypass flap control box => Connections. If the line is tight, carefully lever it off with a screwdriver. Then pull the control pressure line off the turbocharger.

Connections

3. Remove the oil extraction line. To do this, screw off the line at the oil guide housing, turbocharger and on the vent line. Counter with an open-ended wrench. -5- Collect emerging oil.

Oil circuit for turbocharger, cylinders 1 to 4

4. Disconnect the coolant return line next to the generator. To do this, remove the spring band clamp and pull off the rubber line. Then loosen the fastening screw on the holding clamp. => Coolant return line

Coolant return line

5. Detach the turbocharger coolant lines from the coolant hoses or coolant guide and from the holding clamps at the engine (leave attached to the turbocharger) => Turbocharger, cylinders 1 to 4, cooling.

Turbocharger, cylinders 1 to 4, cooling

6. Release the sheetmetal holder on the oil supply line. To do this, loosen the fastening nut (M6). -arrow-

Sheetmetal holder on oil supply line

Oil circuit for turbocharger, line connection, cylinders 1 to 4

7. Disconnect the oil supply line at the cylinder head. => Oil supply line

Oil supply line

8. Remove the turbocharger. To do this, loosen the three fastening screws -1- and remove the turbocharger with the lines attached.
The seal between the elbow and the turbocharger must not be re-used.

Turbocharger fastening screws

Removing turbocharger, cylinder bank 5 - 8

Information

- The turbocharger is removed from the engine with all lines fitted. To do this, detach the lines at the connection points on the engine side and remove the turbocharger. Only disconnect the lines on the turbocharger if they are damaged or if the turbocharger has to be replaced.

- When removing the turbocharger take note of the connection points for the lines.

- If the lines that are screwed to the turbocharger need to be disconnected, their position must be marked before disconnecting them. During reinstallation, the lines must be tension-free and must not be bent.

Information

- The pictures shown in this document may differ from the original.

- However, this does not affect the validity and relevance of the pictures.

Turbocharger, cylinders 5 - 8

NOTICE

Sheared-off sealing grommet on turbocharger intake pipe

- Risk of damage to turbocharger

-> A previously used intake pipe must not be re-used
-> Replace intake pipe and sealing grommet
-> Replace hose clamp
-> Coat area around sealing grommet on new intake pipe with water during fitting

1. Remove the right intake pipe on the turbocharger. Loosen the screw-type clamp -1- for this purpose.
The hose -2- for positive crankcase ventilation must not be removed.

Intake pipe

2. Loosen and release the turbocharger vent lines at the turbocharger and engine -4-. To do this, loosen the union nut on the oil extraction line (counter!) and the holding clamps.
Remove the oil extraction lines at the oil guide housing and turbocharger -8-.

Oil circuit for turbocharger, cylinders 5 to 8

3. Detach the turbocharger coolant lines from the coolant hoses or coolant guide and from the holding clamps at the engine (leave attached to the turbocharger) => Turbocharger, cylinders 5 to 8, cooling.

Turbocharger, cylinders 5 to 8, cooling

4. Pull hose line off the bypass flap control box -top arrow-. If the line is tight, carefully lever it off with a screwdriver.

Connections

5. Disconnect the oil supply line at the cylinder head. Then loosen the sheetmetal holder. => Oil supply line at cylinder head

Oil supply line at cylinder head

6. Remove the turbocharger. To do this, loosen the three fastening screws -1- and pull the turbocharger out sideways.
The seal between the elbow and the turbocharger must not be re-used.

Turbocharger fastening screws

Installing turbocharger

Installing turbocharger, cylinder bank 1 - 4

Information

Seals and sealing rings on the lines must always be replaced.

Information

- If the hose line of the vacuum unit is difficult to fit, moisten it with water.

Information

- The 3 fastening screws of the turbocharger may only be greased on the thread, but not below the head.

Information

- The turbocharger with lines attached is held in one hand. Use your other hand to fit the lines on the engine first, then secure the turbocharger hand-tight to the exhaust manifold with three screws.

Information

- The tightening specifications for the basic engine are stored centrally. -> 1001IN Tightening torques, tightening sequences, assembly overviews [1][2]Specifications. Tightening torques and assembly instructions for other assemblies (e.g. chassis, electrics, transmission or body) or for peripheral engine equipment can be found in the corresponding documents.

Information

- The pictures shown in this document may differ from the original.

- However, this does not affect the validity and relevance of the pictures.

1. Clean sealing faces between the turbocharger and exhaust manifold and replace the seal. -3-

Exhaust manifold on turbo engine, cylinders 1 to 4

2. Carefully move the turbocharger with lines attached into installation position. Fit new sealing rings hand-tight on the lines.
3. Screw turbocharger onto the elbow. Grease the thread of the three fastening screws -1- (M8 x 75) with Microgleit LP 475 mounting paste (000.043.206.95, status 08/09). Tighten the screws (in two stages) to the specified torque.

Turbocharger fastening screws

4. Fit the coolant line on the generator. To do this, push on the rubber hose and fit the spring band clamp. Then position the clamp and tighten the fastening screw to the specified torque.

Coolant line

Turbocharger, cylinders 1 to 4, cooling

5. Screw in oil supply line with new sealing ring on the cylinder head and tighten to the specified torque. Then position the holding clamp and tighten the fastening screw to the specified torque -arrow-.

Oil supply line

Sheetmetal holder on oil supply line

Oil circuit for turbocharger, cylinders 1 to 4

6. Attach control line to the turbocharger. Secure the line with a new sheetmetal clip. Then attach the control line to the pressure unit => Control line.

Control line

NOTICE

Sheared-off sealing grommet on turbocharger intake pipe

- Risk of damage to turbocharger

-> A previously used intake pipe must not be re-used
-> Replace intake pipe and sealing grommet
-> Replace hose clamp
-> Coat area around sealing grommet on new intake pipe with water during fitting

7. Fit new intake pipe -1- with new sealing grommet and hose clamp -2- on the turbocharger.

Intake pipe on turbocharger

Installing turbocharger, cylinder bank 5 - 8

Information

Seals and sealing rings on the lines must always be replaced.

Information

- The 3 fastening screws of the turbocharger may only be greased on the thread, but not below the head.

Information

- If the hose line of the vacuum unit is difficult to fit, moisten it with water.

Information

- The turbocharger with lines attached is held in one hand. Use your other hand to fit the lines on the engine first, then secure the turbocharger hand-tight to the exhaust manifold with three screws.

Information

- The tightening specifications for the basic engine are stored centrally. -> 1001IN Tightening torques, tightening sequences, assembly overviews [1][2]Specifications. Tightening torques and assembly instructions for other assemblies (e.g. chassis, electrics, transmission or body) or for peripheral engine equipment can be found in the corresponding documents.

Information

- The pictures shown in this document may differ from the original.

- However, this does not affect the validity and relevance of the pictures.

1. Clean sealing faces between the turbocharger and exhaust manifold and replace the seal. -4-

Exhaust manifold on turbo engine, cylinders 5 to 8

Turbocharger fastening screws

4. Screw in oil supply line with new sealing ring on the cylinder head and tighten to the specified torque. => Oil supply line. Then position the holding clamp and tighten the fastening screw to the specified torque.

Oil supply line

5. Fit oil extraction line -8-. Fit vent line (counter!) -4-.

Oil circuit for turbocharger, cylinders 5 to 8

6. Fit coolant lines and coolant hoses => Turbocharger, cylinders 5 to 8, cooling.

Turbocharger, cylinders 5 to 8, cooling

7. Fit the hose line at the bypass flap control box -top arrow-.

Connections

NOTICE

Sheared-off sealing grommet on turbocharger intake pipe

- Risk of damage to turbocharger

-> A previously used intake pipe must not be re-used
-> Replace intake pipe and sealing grommet
-> Replace hose clamp
-> Coat area around sealing grommet on new intake pipe with water during fitting

8. Fit new intake pipe with new sealing grommet and hose clamp -1- on the turbocharger. => Intake pipe

Intake pipe

Subsequent work

Subsequent work for removing and installing turbocharger

1. Install primary catalytic converters. -> 267619 Removing and installing primary catalytic converter - section on "Installing" 267619 Removing and installing primary catalytic converter
2. Install engine. -> 100119 Removing and installing engine - section on "Installing" 100119 Removing and installing engine
3. Fill in engine oil. -> 170101 Checking engine-oil level Procedures