Turbocharger Assembly Overview

Turbocharger Assembly Overview

CAUTION!
If mechanical damage is found on exhaust turbocharger, e.g. a destroyed compression wheel, it is not enough to just replace the turbocharger. Perform the following steps to prevent subsequent damage.

• Check the air filter housing, the air filter insert and the intake hoses for contamination.

• Check entire charge air circuit and cooler for contamination.

If contaminants are found in charge air circuit, circuit must be cleaned and cooler replaced if necessary.

• Various hose connections are secured.

• Charge air system must be properly sealed.

• Replace self-locking nuts.

• Before installing oil supply line, fill turbocharger with engine oil at filler tube.

• After installing turbocharger, let engine run at idle for approximately 1 minute and without increasing engine speed. This ensures that turbocharger is lubricated.

• The components illustrated correspond to cylinder bank 1. They are a mirror image of the components for cylinder bank 2.

Observe safety precautions. Refer to --> [ Safety Precautions ] Safety Precautions.

Observe rules for cleanliness. Refer to --> [ Clean Working Conditions ] Clean Working Conditions.





1 To connecting pipe

• Vehicles with engine code BKW --> [ (Item 12) Connecting pipe ] Removal and Replacement.

• Vehicles with engine code BWF --> [ (Item 11) Connecting pipe ] Removal and Replacement.

2 Exhaust manifold

• Assembly overview, refer to --> [ Exhaust Manifold Assembly Overview ] Exhaust Manifold Assembly Overview.

3 Turbocharger intake temperature sensor, 45 Nm

• Only on vehicles with engine code BWF.

Cylinder bank 1:

• Exhaust Gas Temperature (EGT) sensor 1 (G235).

Cylinder bank 2:

• Bank 2 EGT sensor 1 (G236).

4 Securing clamp, 8 Nm

5 Turbocharger

• Can only be replaced when engine is removed from engine compartment, refer to --> [ Engine, Removing ] Engine Removing.

• Tighten oil supply line to 23 Nm.

• When installing, tighten the clamp (item 4) first and then the turbocharger.

6 To front exhaust pipe with catalytic converter

• Vehicles with engine code BKW --> [ (Item 7) Front exhaust pipe with catalytic converter ] Service and Repair.

• Vehicles with engine code BWF --> [ (Item 12) Front exhaust pipe with catalytic converter ] .

7 40 Nm

8 Servo motor for turbocharger

• Component of the turbocharger cannot be replaced.

Cylinder bank 1:

• Turbocharger 1 servo motor (V280).

Cylinder bank 2:

• Turbocharger 2 servo motor (V281).

9 Seal

• Replace.

• Before installing, check the sealing surfaces for contamination and clean if necessary.

10 8 Nm

11 Connecting pipe

12 To charge air tube

• --> [ (Item 8) Charge air pipe ] Service and Repair.

13 Sealing sleeve

• Replace if damaged.

• Ensure seated tightly.

14 Connecting pipe

• From crankcase ventilation valve.