Installing the exhaust turbocharger (cylinder head removed)

CAUTION: Heavy component .
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 exhaust 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 exhaust turbocharger is only permitted with mounted special tool 2 466 919.

Check stud bolts (1) for damage and replace if necessary.
Parts: Stud bolts

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

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If necessary, unscrew or screw in the stud bolts further.
Check the stud bolts in the marked area for damage, replace as appropriate.
Parts: Stud bolts

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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.
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Clean the sealing surfaces (1) on the cylinder head using special tool 0 495 102 (11 4 470) .
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 exhaust turbocharger using special tool 0 495 102 (11 4 470) .

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Replace the seal (1).
Parts: Seal
Feed in the seal (1) in the marked area and install.

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CAUTION:
Heavy component .
Heavy components can lead to injury or damage .
- Remove and install heavy components with the aid of another person/other persons.
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Insert and install the exhaust turbocharger (1).
Thermal compensating element of the exhaust 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 .

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Tighten the nuts in the sequence (1) to (7).

TIGHTENING TORQUE SPECIFICATION

Exhaust manifold to cylinder head
Flange nut M7	Replace flange nuts 1. Joining torque	10 Nm
	2. Joining torque	10 Nm
	3. Joining torque	16 Nm
	4. Joining torque	16 Nm
	5. Joining torque	16 Nm

Fig 1: Exhaust Turbocharger Nuts Tightening Sequence

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Ensure that the thermal compensating elements (A) are not damaged.
Loosen nuts (1) and (2).
Guide out the special tool 2 466 467 on the exhaust turbocharger (3) and remove.

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Release the nuts (1) and (2).
Guide out the special tool 2 466 467 on the exhaust turbocharger (3) and remove.

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Loosen screw (2).
Feed out the bracket (1) of the special tool 2 446 919 and set it aside.

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Release the clamping lever (1) of the special tool 2 446 919 in arrow direction .

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Loosen screw (1).
Guide out the special tool 2 446 919 on the exhaust turbocharger and remove.

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