Removal And Installation: Turbocharger
Special tools and workshop equipment required
- Engine Bung Set VAS 6122
Removing
If mechanical damage (such as a destroyed compression wheel) is found on the turbocharger, just replacing the turbocharger is not enough. To avoid damage later, perform the following steps:
- Check the air filter housing, air filter element and air guide hoses for contamination.
- Check the entire charge air circuit and charge air cooler for foreign objects.
- If there are foreign objects in the charge air system, clean the charge air circuit and replace the charge air cooler if necessary.
-- Carefully pull the engine cover -arrows- off the 4 bolts one after the other.
-- Remove the air guide hose by loosening the hose clamps -arrows-.
Vehicles Built through 05.10:
-- Remove the bolts -2- and -3-.
-- Loosen the clamp -1- and remove the air guide hose from the right air guide pipe.
Vehicles Built from 06.10:
-- Remove the bolts -2- and -3-.
-- Loosen the clamp -1- and remove the air guide hose from the right air guide pipe.
All Vehicles:
-- Remove the bolts -left arrows- and move the air intake connection to the side with the air duct hose still connected -right arrow-.
-- Disconnect the connector -2- on the turbocharger 1 servo motor -V280-.
-- Remove the bolt -1- and banjo bolt -3- for the oil supply line on the turbocharger.
-- Remove the bolts -1- and -2- and then remove the heat shield from the turbocharger.
-- Remove the nuts -arrows- and remove the primary catalytic converter from the turbocharger.
-- Disconnect the exhaust gas temperature sensor 1 -G235- connector -1- (black).
Ignore -2-.
-- Remove the turbocharger bolts -arrows-.
Danger of damaging both pipes for the oil return line.
- The upper section -3- of the oil return line mounted to the turbocharger must be removed carefully from the lower section -5- of the oil return line.
- Gently turning the turbocharger -4- back and forth and pulling it up will prevent bending the oil return line pipes.
- O-ring
- Intermediate flange
-- Remove the turbocharger.
-- Seal the open lines and connections with clean plugs from the VAS 6122.
Do not set the removed turbocharger on top the upper section of the oil return line.
Installing
- For the correct tightening specifications, refer to TURBOCHARGER OVERVIEW .
Replace seals, gaskets and O-rings.
Fill the turbocharger with engine oil at the oil supply line connection.
The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing.
Secure all hose connections with hose clamps appropriate for the model.
To ensure the turbocharger is supplied with enough oil, let the engine run at idle for approximately 1 minute after installing the turbocharger. Do not increase the engine speed during this time.
-- Install the new O-ring -1- on the lower part -5- of the oil return line.
-- Lightly coat the O-ring and the inner sealing surface of the upper section -3- of the oil return line with oil.
-- Guide the oil return line upper section -3- through the intermediate flange -2- to the oil return line lower section -5- when installing the turbocharger -4-.
Danger of damaging the O-ring.
- Carefully attach the upper section -3- of the oil return line to the lower section -5- of the oil return line.
-- Tighten the turbocharger -arrows-.
The rest of the installation is performed in reverse order of removal, noting the following:
-- Install primary catalytic converter. Refer to PRIMARY CATALYTIC CONVERTER .
-- Install the air guide pipe. Refer to AIR DUCT PIPES AND AIR DUCT HOSES OVERVIEW, VEHICLES BUILT THROUGH 05.10 .
-- Install the air duct hoses and screw-type clamps. Refer to Figure.