Turbocharger: Service and Repair
WM 213019 Removing and installing turbocharger
Preliminary work
1. Remove the engine.
-> 100119 Removing and installing engine 100119 Removing and installing engine
2. Remove primary catalytic converter.
-> 267619 Removing and installing primary catalytic converter (Turbo) Service and Repair
Removing turbocharger at cylinders 1 - 4
Information
- When removing the turbocharger take note of the connection points for the lines.
- The installation position of the lines that are bolted onto the turbocharger must be marked before disconnecting them.
- During reinstallation, the lines must be stress-free and must not be bent.
1. Remove oil lines, coolant lines and heat shield at the turbocharger.
Oil circuit for turbocharger, cylinders 1 to 4
Turbocharger, cylinders 1 to 4 - cooling
1.1. Remove fastening screws for oil extraction line -7- at the turbocharger.
1.2. Remove fastening screws for oil extraction line -6- at the oil guide housing.
1.3. Remove fastening screw for holder of turbocharger vent line -1-. => Holder fastening screw
Holder fastening screw
1.4. Remove fastening screw for coolant return line -1- at the turbocharger.
1.5. Remove turbocharger heat shield.
Turbocharger heat shield (cylinders 5 - 8 shown here)
1.5.1. Remove the three fastening screws -A, B, C- for the heat shield.
1.5.2. Remove heat shield by rotating downwards -D-.
1.6. Remove fastening screw for oil feed line -2- at the turbocharger.
1.6.1. Remove fastening screw -6- for holder -3-.
1.7. Remove fastening screw for coolant supply line -2- at the turbocharger.
1.7.1. Take coolant supply line out of the clamp -3-.
2. Pull off line at turbocharger check valve. => Check valve line (cylinders 5 - 8 shown here)
Check valve line (cylinders 5 - 8 shown here)
3. Remove the fastening screws -1 to 12- for the turbocharger.
Fastening screws for turbocharger exhaust manifold
4. Remove turbocharger -1- , seal -2- and tab washers -3 and 4-.
Turbocharger exhaust manifold, cylinders 1 to 4
Removing turbocharger at cylinders 5 - 8
Information
- When removing the turbocharger take note of the connection points for the lines.
- The installation position of the lines that are bolted onto the turbocharger must be marked before disconnecting them.
- During reinstallation, the lines must be stress-free and must not be bent.
1. Remove oil lines, coolant lines and heat shield at the turbocharger.
Oil circuit for turbocharger, cylinders 5 to 8
Turbocharger, cylinders 5 to 8, cooling
1.1. Remove fastening screws for oil extraction line -6- at the turbocharger.
1.2. Remove fastening screws for oil extraction line -3- at the oil guide housing.
1.3. Remove fastening screw -3- for retaining clamp -4- and take oil line out of holder.
1.4. Remove fastening screw for ventilation pipe holder on the cylinder head. => Ventilation pipe holder
Ventilation pipe holder
1.5. Remove fastening screw for coolant supply line -2- at the turbocharger.
1.5.1. Remove fastening screw for coolant supply line holder -3- at the oil guide housing.
1.6. Remove turbocharger heat shield.
Turbocharger heat shield
1.6.1. Remove the three fastening screws -A, B, C- for the heat shield.
1.6.2. Remove heat shield by rotating downwards -D-.
1.7. Remove fastening screw for oil feed line -1- at the turbocharger.
1.8. Remove fastening screw for coolant return line -1- at the turbocharger.
2. Pull off line at turbocharger check valve. => Check valve line
Check valve line
3. Remove the fastening screws -1 to 12- for the turbocharger.
Fastening screws for turbocharger exhaust manifold
4. Remove turbocharger -1- , seal -2- and tab washers -4 and 5-.
Turbocharger exhaust manifold, cylinders 5 to 8
Installing turbocharger
Installing turbocharger at cylinders 1 - 4
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
Seals and sealing rings on the lines must always be replaced.
1. Clean sealing faces between turbocharger and exhaust manifold and replace seal -2-.
1.1. Fit turbocharger -1- , seal -2- and tab washers -3 and 4-.
Turbocharger exhaust manifold, cylinders 1 to 4
2. Fit the turbocharger fastening screws in the prescribed sequence -1 to 12-.
Fastening screws for turbocharger exhaust manifold
3. Fit line at turbocharger check valve. => Check valve line (cylinders 5 - 8 shown here)
Check valve line (cylinders 5 - 8 shown here)
4. Fit oil lines, coolant lines and heat shield at the turbocharger.
Oil circuit for turbocharger, cylinders 1 to 4
Turbocharger, cylinders 1 to 4 - cooling
4.1. Fit fastening screw for coolant supply line -2- at the turbocharger.
4.1.1. Secure coolant supply line in place in clamp -3-.
4.2. Fit fastening screw for oil feed line -2- at the turbocharger.
4.2.1. Fit fastening screw -6- for holder -3-.
4.3. Fit turbocharger heat shield.
Turbocharger heat shield (cylinders 5 - 8 shown here)
4.3.1. Insert heat shield by rotating upwards -D-.
4.3.2. Fit the three fastening screws -A, B, C- for the heat shield.
4.4. Fit fastening screw for coolant return line -1- at the turbocharger.
4.5. Fit fastening screw for holder of turbocharger vent line -1-. => Holder fastening screw
Holder fastening screw
4.6. Fit fastening screws for oil extraction line -6- at the oil guide housing.
4.7. Fit fastening screws for oil extraction line -7- at the turbocharger.
Installing turbocharger at cylinders 5 - 8
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
Seals and sealing rings on the lines must always be replaced.
1. Clean sealing faces between turbocharger and exhaust manifold and replace seal -2-.
1.1. Fit turbocharger -1- , seal -2- and tab washers -4 and 5-.
Turbocharger exhaust manifold, cylinders 5 to 8
2. Fit the turbocharger fastening screws in the prescribed sequence -1 to 12-.
Fastening screws for turbocharger exhaust manifold
3. Fit line at turbocharger check valve. => Check valve line
Check valve line
4. Fit oil lines, coolant lines and heat shield at the turbocharger.
Oil circuit for turbocharger, cylinders 5 to 8
Turbocharger, cylinders 5 to 8, cooling
4.1. Fit fastening screw for coolant return line -1- at the turbocharger.
4.2. Fit fastening screw for oil feed line -1- at the turbocharger.
4.3. Fit turbocharger heat shield.
Turbocharger heat shield
4.3.1. Insert heat shield by rotating upwards -D-.
4.3.2. Fit the three fastening screws -A, B, C- for the heat shield.
4.4. Fit fastening screw for coolant supply line -2- at the turbocharger.
4.4.1. Fit fastening screw for coolant supply line holder -3- at the oil guide housing.
4.5. Fit fastening screw for ventilation pipe holder on the cylinder head. => Ventilation pipe holder
Ventilation pipe holder
4.6. Insert oil line into holder and fit fastening screw -3- for retaining clamp -4-.
4.7. Fit fastening screws for oil extraction line -3- at the oil guide housing.
4.8. Fit fastening screws for oil extraction line -6- at the turbocharger.
Subsequent work
1. Install the engine.
-> 100119 Removing and installing engine 100119 Removing and installing engine
2. Install primary catalytic converter.
-> 267619 Removing and installing primary catalytic converter (Turbo) Service and Repair