Turbocharger Components

Charge air pressure system with turbocharger

WARNING:
Observe the following for all installations, especially in engine compartment due to lack of room
Route lines of all types (e.g. for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.
Watch for sufficient clearance to all moving or hot components.

Observe rules for cleanliness. [1][2]Technician Safety Information

NOTE: All hose connections are secured with clamps.
Charge air system must be properly sealed.
Always replace self-locking nuts.
Charge pressure hoses and their connections must be free of grease before re-installation.

Turbocharger with attachments, removing and installing






1. Exhaust manifold

2. Gasket
Always replace
Note installed position

3. Seal
Always replace

4. Connecting piece, 30 Nm
5. From oil filter bracket

6. Oil supply line
Tighten to 25 Nm

7. Coolant return line
Tighten to 30 Nm

8. To upper coolant line
9. Connecting piece, 35 Nm
10. Washer

11. 30 Nm
Always replace
Coat threads with G 052 112 A3

12. Banjo fitting, 35 Nm
13. To engine block

14. Hose
To Wastegate Bypass Regulator Valve -N75-

15. Banjo fitting, 35 Nm
16. Coolant supply line
17. 10 Nm

18. Hose
To Wastegate Bypass Regulator Valve -N75-

19. Banjo fitting, 15 Nm

20. Bracket
Between turbocharger and cylinder block

21. 25 Nm
22. From air filter
23. To charge air pressure cooler
24. 10 Nm
25. Locking screw, 15 Nm

26. Oil return line
To oil pan

27. 10 Nm

28. Turbocharger
Checking charge air pressure regulation, refer to Testing and Inspection - Procedures Testing and Inspection
The charge air pressure regulation valve and vacuum diaphragm for charge air pressure regulation valve are part of the exhaust turbocharger and cannot be replaced individually.
Before connecting oil supply line, fill turbocharger with oil at filler tube
After installing turbocharger, let engine idle for approx. 1 minute without increasing engine speed. This ensures adequate oil supply to the turbocharger.

29. 30 Nm
Always replace
Coat threads with G 052 112 A3

30. Catalytic converter

31. 35 Nm
Always replace
Coat threads and bolt head contact surface with G 052 112 A3