Installing turbocharger
CAUTION:
Heavy component.
Heavy components can lead to injury or damage.
Heavy components can lead to injury or damage.
- Remove and install heavy components with the aid of another person/other persons.
NOTE:
risk of damage
Damage of the electric wastegate valve controller.
Excessive force when removing and installing a jammed turbocharger may damage the electric wastegate valve controller.
Damage of the electric wastegate valve controller.
Excessive force when removing and installing a jammed turbocharger may damage the electric wastegate valve controller.
- Do not pull on the electrical wastegate valve controller or on the coupling rod.
- Apply force only at the turbine housing and exhaust manifold.
- Do not pull on the compressor housing.
NOTE:
TECHNICAL INFORMATION
Do not damage the thermal compensating elements. Disassembly and installation including intermediate storage of the turbocharger is only permitted with mounted special tool 2 466 919.
Do not damage the thermal compensating elements. Disassembly and installation including intermediate storage of the turbocharger is only permitted with mounted special tool 2 466 919.
- Check screw-in depth (A)
of upper stud bolts (1)
.TECHNICAL DATA SPECIFICATION
Screw-in depth of upper stud bolts on cylinder head Dimension A 30 mm - If necessary, screw in or unscrew the stud bolts further.NOTE: RISK OF DAMAGE
Damage to the surface.
The use of metal-cutting tools (e.g., emery cloths) for cleaning surfaces can damage them and lead to leaks and/or engine damage.- Do not use any metal-cutting tools.
- Clean the sealing surfaces (1)
on the cylinder head using special tool 0 495 102 (11 4 470).
- Replace the seal (1)
.
Parts: Seal
- Feed in the seal (1)
in the marked area
and install.NOTE: RISK OF DAMAGE
Damage to the surface.
The use of metal-cutting tools (e.g., emery cloths) for cleaning surfaces can damage them and lead to leaks and/or engine damage.- Do not use any metal-cutting tools.
- Clean the sealing surfaces (1)
on the turbocharger using special tool 0 495 102 (11 4 470). CAUTION: Heavy component.
Heavy components can lead to injury or damage.- Remove and install heavy components with the aid of another person/other persons.
- Insert and install the turbocharger (1) .
- Thermal compensating element of the turbocharger (1)
or the exhaust manifold should not
be bent or deformed.
- Feed in and install the shifting strip (1) .
- Install the sliding rail (1)
in such a way that the part number is visible.
- Tighten the nuts in the sequence (1)
to (7)
.TIGHTENING TORQUES SPECIFICATION
Exhaust manifold to cylinder head Flange nut M7
Replace flange nuts1. Joining torque 10 Nm 2. Joining torque 10 Nm 3. Joining torque 16 Nm 4. Joining torque 16 Nm 5. Joining torque 16 Nm - Ensure that thermal compensating elements (A) are not damaged.
- Loosen nuts (1) and (2) .
- Guide out the special tool 2 466 467
on the turbocharger (3)
and remove.
- Release the nuts (1) and (2) .
- Guide out the special tool 2 466 467
on the turbocharger (3)
and remove.
- Loosen screw (2) .
- Feed out the bracket (1)
of the special tool 2 446 919
and set it aside.
- Release clamping lever (1)
of special tool 2 446 919
in the arrow direction.
- Loosen screw (1) .
- Guide out the special tool 2 446 919
on the turbocharger and remove.
- Replace the sealing rings (1)
on the coolant feed line (2)
for the turbocharger using the special tool 0 496 714 (00 9 030).
Parts: Sealing ring
- Feed in and install the coolant feed line for the turbocharger (3) .
- Tighten down screw (1)
.TIGHTENING TORQUES SPECIFICATION
Coolant feed line to crankcase M6X12 tightening torque 8 Nm - Tighten down screw (2)
.TIGHTENING TORQUES SPECIFICATION
Coolant feed line to crankcase M6X12 tightening torque 8 Nm - Replace screws (1)
and (2)
.
Parts: Screws
- Feed in and install support (3) .
- Tighten down screws (2)
.TIGHTENING TORQUES SPECIFICATION
Turbocharger support to crankcase M8x20
Replace screws.tightening torque 19 Nm - Tighten down screws (1)
.TIGHTENING TORQUES SPECIFICATION
Turbocharger to support M8 x 25
Replace screw.tightening torque 19 Nm - Replace the sealing rings (1)
at the oil feed line (2)
for the turbocharger using the special tool 0 496 714 (00 9 030).
Parts: Sealing ring
- Feed in and install the oil feed line (2) for the turbocharger.
- Tighten down screw (1)
.TIGHTENING TORQUES SPECIFICATION
Oil feed line for turbocharger to crankcase M6 x 12
Replace sealing ring.tightening torque 8 Nm - Tighten screw (1)
on the coolant return line (2)
.TIGHTENING TORQUES SPECIFICATION
Coolant return line holder to crankcase M6X12 tightening torque 8 Nm - Connect and lock the coolant return line (1)
to the coolant pump (2)
for the turbocharger.
The coolant return line (1) must engage audibly.
- Feed in and install the heat shield (2) .
- Replace screws (1)
.
Parts: Screws
Tighten down screws (1) .
TIGHTENING TORQUES SPECIFICATIONHeat shield to cylinder head M8X12
Replace screws.tightening torque 19 Nm - Feed in and install the heat shield (3) .
- Replace screws (1)
.
Parts: Screws
Tighten down screws (1) .
TIGHTENING TORQUES SPECIFICATIONHeat shield to cylinder head M8X12
Replace screws.tightening torque 19 Nm - Replace the screw (2)
.
Parts: Screw
Tighten down screw (2) .
TIGHTENING TORQUES SPECIFICATIONHeat shield to trim strip M6X16
Replace screw.Tightening torque 8 Nm
Follow-up work
- Refer to INSTALLING THE OIL RETURN LINE FOR THE TURBOCHARGER .
- Refer to INSTALLING CATALYTIC CONVERTER .
- Refer to INSTALLING THE COMPLETE EXHAUST SYSTEM .
- Refer to INSTALLING THE CONNECTING SUPPORTS ON THE TUNNEL .
- Refer to INSTALLING THE REAR LEFT TORSION STRUT .
- Refer to INSTALLING THE OXYGEN SENSOR MONITOR .
- Refer to INSTALLING LAMBDA OXYGEN SENSOR .
- Refer to ATTACHING THE BRACKET OF THE POSITIVE BATTERY CABLE .
- Refer to INSTALLING THE ADAPTER FOR THE ENGINE VENTILATION LINE WITH THE HEATING ELEMENT ON THE TURBOCHARGER .
- Refer to INSTALLING CHARGE AIR LINE .
- Refer to INSTALLING CLEAN AIR PIPE .
- Refer to INSTALLING ENGINE VENTILATION LINE .
- Refer to INSTALLING INTAKE FILTER HOUSING .
- Refer to INSTALLING FAN COWL .
- Refer to INSTALLING THE REAR CROSS CONNECTION .
- Refer to INSTALLING FRONT-END STRUT ON LEFT AND RIGHT .
- Refer to INSTALLING FRONT CROSS CONNECTION .
- Refer to INSTALLING THE SEAL FOR THE HOOD GASKET LEFT AND RIGHT .
- Refer to INSTALLING THE FRONT HOOD SEAL .
- Refer to INSTALLING ACOUSTIC COVER AT REAR .
- Refer to INSTALLING THE REAR HOOD SEAL .
- Refer to FILLING THE HIGH-TEMPERATURE COOLING SYSTEM WITH THE VACUUM FILLING EQUIPMENT .
- Refer to VENTING THE HIGH-TEMPERATURE COOLANT SYSTEM .
- Refer to CHECKING ENGINE OIL LEVEL .
- Refer to INSTALLING ACOUSTIC COVER .
- Refer to INSTALLING THE STIFFENING PLATE .
- Refer to INSTALLING UNDERBODY PROTECTION AT REAR .
- Refer to INSTALLING FRONT UNDERBODY PROTECTION .
- Refer to TAKING HOOD OUT OF THE SERVICE POSITION .