Installing turbocharger

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 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.

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.

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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 the seal (1).
Parts: Seal
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 0 495 102 (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 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.

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Tighten the nuts in the 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

Fig 1: Exhaust Manifold Nuts Tightening Sequence

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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.

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Release the nuts (1) and (2).
Guide out the special tool 2 466 467 on the 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 clamping lever (1) of 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 turbocharger and remove.

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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

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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

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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: Screws
Feed in and install support (3).
Tighten down screws (2).

TIGHTENING TORQUES SPECIFICATION

Turbocharger support to crankcase
M8 x 20 Replace screws.	Tightening torque	19 Nm

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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

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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

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Tighten screw (1) on the coolant return line (2).

TIGHTENING TORQUES SPECIFICATION

Coolant return line holder to crankcase
M6X12	tightening torque	8 Nm

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Connect and lock the coolant return line (1) to the coolant pump (2) for the turbocharger.
The coolant return line (1) must engage audibly.

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Feed in and install the heat shield (2).
Replace screws (1).
Parts: Screws

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: Screws

Tighten down screws (1).

TIGHTENING TORQUES SPECIFICATION

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

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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

Follow-up work

Refer to INSTALLING THE ADAPTER FOR THE ENGINE VENTILATION LINE WITH THE HEATING ELEMENT ON THE TURBOCHARGER .
Refer to INSTALLING THE OIL RETURN LINE FOR THE 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 MOUNT OF HOOD SEAL ON THE 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 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 INSTALLING THE FRONT BOTTOM RIGHT WHEEL ARCH COVER .
Refer to INSTALLING THE CENTER UNDERBODY PROTECTION .
Refer to INSTALLING FRONT UNDERBODY PROTECTION .
Refer to INSTALLING UNDERBODY PROTECTION AT REAR .
Refer to INSTALLING ACOUSTIC COVER .
Refer to TAKING HOOD OUT OF THE SERVICE POSITION .