Turbocharger, Assembly Overview

Turbocharger, Assembly Overview





Teil I - Engine Codes BZB and CGYA => [ Part I, Engine Code BZB and CGYA ]

Teil I - Engine codes CAWB, CBFA, CCTA and CCTB => [ Part I, Engine Codes CAWA, CAWB, CBFA, CCTA and CCTB ]

Teil II - => [ Part II ]

Teil III - => [ Part III ]

Teil IV - => [ Part IV ]

Part I, Engine Code BZB and CGYA





1 Turbocharger

• Can only be replaced with exhaust manifold and pressure unit.

• Removing and installing => [ Turbocharger, Removing and Installing ] [1][2]Turbocharger

2 To EVAP canister

3 Turbocharger and vacuum diaphragm

• checking => [ Turbocharger Vacuum Diaphragm, Checking ] Turbocharger Vacuum Diaphragm, Checking

• Removing and installing => [ Turbocharger Vacuum Diaphragm, Removing and Installing ] Service and Repair

• Adjusting => [ Turbocharger Vacuum Diaphragm, Engine Code BZB and CGYA, Adjusting ].

4 Seal

• Replace

5 Nipple

6 Banjo bolt

• 8 Nm

7 Hose

8 Hose

9 Bolt

• 3 Nm

10 Wastegate Bypass Regulator Valve (N75)

11 Hose

12 Seal

• Replace

13 Connection

14 Securing clip

15 Bolt

• 9 Nm

16 Bolt

• 7 Nm

17 Turbocharger Recirculating Valve (N249)

• Note installation position => [ Installation position of ]

18 Seal

• Replace

Part I, Engine Codes CAWA, CAWB, CBFA, CCTA and CCTB





1 Turbocharger

• Can only be replaced with exhaust manifold and pressure unit.

• Removing and installing => [ Turbocharger, Removing and Installing ] [1][2]Turbocharger

2 To EVAP canister

3 Turbocharger vacuum diaphragm

• checking => [ Turbocharger Vacuum Diaphragm, Checking ] Turbocharger Vacuum Diaphragm, Checking

• Removing and installing => [ Turbocharger Vacuum Diaphragm, Removing and Installing ] Service and Repair

4 Hose

5 Hose

6 Bolt

• 3 Nm

7 Wastegate Bypass Regulator Valve (N75)

8 Hose

9 Connection

10 Securing clip

11 Bolt

• 9 Nm

12 Seal

• Replace

13 Turbocharger Recirculating Valve (N249)

• Note installation position => [ Installation position of ]

14 Bolt

• 7 Nm

15 Seal

• Replace

Part II





1 Seal

• Replace

2 Bolt

• 20 Nm + 45° (1/8 turn further)

3 Oil supply line

4 Turbocharger

• Can only be replaced with exhaust manifold and pressure unit.

• Removing and installing => [ Turbocharger, Removing and Installing ] [1][2]Turbocharger

5 Bolt

• 9 Nm

6 Bolt

• 9 Nm

7 Seal

• Replace

8 Bolt

• 20 Nm + 45° (1/8 turn further)

9 Bolt

• 9 Nm

10 Bolt

• 20 Nm + 45° (1/8 turn further)

11 Seal

• Replace

12 Coolant supply line

13 O-ring

• Replace

14 Bolt

• 9 Nm

15 Gasket

• Replace

16 Oil return line

17 Bolt

• 9 Nm

18 Gasket

• Replace

Part III





1 Gasket

• Replace

2 Nut

• Tightening order => [ Turbocharger - tightening sequence ]

• Replace

• Coat the studs of the exhaust manifold with hot bolt paste; Hot bolt paste

3 Bolt

• 20 Nm + 45° (1/8 turn further)

4 Seal

• Replace

5 Coolant return line

6 Bolt

• 9 Nm

7 Turbocharger

• Can only be replaced with exhaust manifold and pressure unit.

• Removing and installing => [ Turbocharger, Removing and Installing ] [1][2]Turbocharger

8 Bracket

9 Bolt

• 30 Nm

• Coat the bolt with hot bolt paste.

10 Bolt

• 30 Nm

• Coat the bolt with hot bolt paste.

11 Nut

• do not loosen to remove turbocharger

• Replace

• 30 Nm

• Coat the studs of the exhaust manifold with hot bolt paste; Hot bolt paste

12 Fastening strip

Turbocharger - tightening sequence





- Tighten the bolts - 1 through 5 - in 4 stages as follows:

- 1. Tighten the bolts to 5 Nm.

- 2. Tighten the bolts to 12 Nm.

- 3. Tighten the bolts to 16 Nm.

- 4. Tighten the bolts to 25 Nm.

Part IV

• Only engine codes BZB and CGYA have an adjustable vacuum diaphragm.





1 Turbocharger

• Can only be replaced with exhaust manifold and pressure unit.

• Removing and installing => [ Turbocharger, Removing and Installing ] [1][2]Turbocharger

2 Turbocharger and vacuum diaphragm

• checking => [ Turbocharger Vacuum Diaphragm, Checking ] Turbocharger Vacuum Diaphragm, Checking

• Removing and installing => [ Turbocharger Vacuum Diaphragm, Removing and Installing ] Service and Repair

• adjusting - engine codes BZB and BGYA only.

3 Bolt

• 10 Nm

4 Nut

• Engine codes BZB and CGYA only

• 9 Nm

• secure with sealing wax

5 Securing plate

• Engine codes BZB and CGYA only

6 Knurled nut

• Engine codes BZB and CGYA only

Installation position of Turbocharger Recirculating Valve (N249)

- Note installation location - arrows -.