Installing exhaust turbocharger

• 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, continue screwing in stud bolts or unscrew.

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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). 
• Replace gasket (1).

  Parts:  Gasket

• Feed in the seal (1) in the marked area  and install.

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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.
• Clean the sealing surfaces (1) on the exhaust turbocharger using special tool 0495 102 (11 4 470). 

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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 shifting strip (1) so that the part number is visible. 

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• Tighten the nuts in sequence (1) to (7).
  TIGHTENING TORQUES 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

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• Make sure 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 the 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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• Replace the sealing rings (1) on the coolant feed line (2) for the exhaust turbocharger with the special tool 0 496 714 (00 9 030). 

  Parts:  Sealing rings

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• Feed in and install the coolant feed line for the exhaust turbocharger (3).
• Tighten down screw (1).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Coolant feed line to crankcase
  M6X12	Tightening torque	8 Nm

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• Tighten down screw (2).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Coolant feed line to crankcase
  M6X12	Tightening torque	8 Nm

• Replace screws (1) and (2).

  Parts:  screw

• Feed in and install the support (3).
• Tighten down screws (2).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Exhaust turbocharger support to crankcase
  M8x20 Replace screws.	Tightening torque	19 Nm

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• Tighten down screws (1).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Exhaust turbocharger to support
  M8x25 Replace screw.	Tightening torque	19 Nm

• Using the special tool 0 496 714 (00 9 030)  , replace the sealing rings (1) on the oil feed line (2) for the exhaust turbocharger.

  Parts:  Sealing rings

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• Insert and install oil feed line (2) for the exhaust turbocharger.
• Tighten down screw (1).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Oil feed line for exhaust turbocharger to crankcase
  M6x12 Replace sealing ring.	Tightening torque	8 Nm

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• Tighten the screw (1) at the coolant return line (2).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Coolant return line holder to crankcase
  M6X12	Tightening torque	8 Nm

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• Connect the coolant return line (1) to the coolant pump (2) for the exhaust turbocharger and lock.

  The coolant return line (1) must engage audibly.

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• Feed in and install the heat shield (2).
• Replace screws (1).

  Parts:  screw

  Tighten down screws (1).

  TIGHTENING TORQUES SPECIFICATION
  
  

  Heat shield to cylinder head
  M8X12 Replace screws.	Tightening torque	19 Nm

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• Feed in and install the heat shield (3).
• Replace screws (1).

  Parts:  screw

  Tighten down screws (1).

  TIGHTENING TORQUES SPECIFICATION
  
  

  Heat shield to cylinder head
  M8X12 Replace screws.	Tightening torque	19 Nm

• Replace the screw (2).

  Parts:  Screw

  Tighten down screw (2).

  TIGHTENING TORQUES SPECIFICATION
  
  

  Heat shield to trim strip
  M6X16 Replace screw.	Tightening torque	8 Nm

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Follow-up work 

• Refer to INSTALLING THE ADAPTER FOR ENGINE VENTILATION LINE WITH HEATING ELEMENT AT THE EXHAUST TURBOCHARGER .
• Refer to INSTALLING THE OIL RETURN LINE FOR THE EXHAUST TURBOCHARGER .
• Refer to INSTALLING CATALYTIC CONVERTER .
• 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 EXHAUST SYSTEM .
• Refer to INSTALLING THE CONNECTING SUPPORTS ON THE TUNNEL .
• Refer to INSTALLING TANK COVER ON LEFT AND RIGHT .
• 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 TOP CROSS CONNECTION .
• Refer to INSTALLING FRONT CROSS CONNECTION .
• Refer to INSTALLING FRONT-END STRUT ON LEFT AND RIGHT .
• Refer to INSTALLING THE SEAL FOR THE HOOD GASKET LEFT AND RIGHT .
• Refer to INSTALLING THE COVER IN THE ENGINE COMPARTMENT AT TOP LEFT AND RIGHT .
• Refer to INSTALLING ACOUSTIC COVER AT REAR .
• Refer to INSTALLING THE COWL UPPER PART .
• Refer to INSTALLING TENSION STRUT ON LEFT AND RIGHT SHOCK TOWER .
• Refer to INSTALLING WINDSHIELD PANEL COVER .
• Refer to INSTALLING LEFT AND RIGHT WIPER ARM .
• Refer to INSTALLING THE REAR RIGHT ENGINE COMPARTMENT COVER .
• Refer to INSTALLING THE COVER OF THE ENGINE COMPARTMENT ON THE REAR LEFT .
• Refer to INSTALLING THE FRONT HOOD SEAL AT THE REAR .
• Refer to FILLING THE HIGH-TEMPERATURE COOLING SYSTEM WITH THE VACUUM FILLING EQUIPMENT .
• Refer to VENTING THE HIGH-TEMPERATURE COOLANT SYSTEM .
• Refer to INSTALLING THE FRONT BOTTOM RIGHT WHEEL ARCH COVER .
• Refer to INSTALLING THE CENTER UNDERBODY PROTECTION .
• Refer to INSTALLING THE FRONT UNDERBODY PROTECTION .
• Refer to INSTALLING UNDERBODY PROTECTION AT REAR .
• Refer to INSTALLING ACOUSTIC COVER .
• Refer to TAKING HOOD OUT OF THE SERVICE POSITION .