Installing exhaust 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 exhaust turbocharger may damage the electric wastegate valve controller .
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 electric wastegate valve controller.
- 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.
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 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 .
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 .
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) .
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.
- 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.
- 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 | |
- Ensure that 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.
- Release the nuts (1) and (2) .
- Guide out the special tool 2 466 467
on the exhaust 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 exhaust turbocharger and remove.
- Replace the sealing rings (1) on the coolant feed line (2) for the exhaust turbocharger using the special tool 0 496 714 (00 9 030) .
Parts: Sealing ring
- Feed in and install the coolant feed line for the exhaust turbocharger (3) .
- Tighten down screw (1) .
TIGHTENING TORQUE SPECIFICATION
| Coolant feed line to crankcase | ||
| M6X12 | tightening torque | 8 Nm |
- Tighten down screw (2) .
TIGHTENING TORQUE 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 TORQUE SPECIFICATION
| Exhaust turbocharger support to crankcase | ||
| M8 x 20 Replace screws. |
Tightening torque | 19 Nm |
- Tighten down screws (1) .
TIGHTENING TORQUE SPECIFICATION
| Exhaust 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 exhaust 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 exhaust turbocharger.
- Tighten down screw (1) .
TIGHTENING TORQUE SPECIFICATION
| Oil feed line for exhaust turbocharger to crankcase | ||
| M6 x 12 Replace sealing ring. |
tightening torque | 8 Nm |
- Tighten screw (1) on the coolant return line (2) .
TIGHTENING TORQUE 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 exhaust 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 TORQUE 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 TORQUE SPECIFICATION
| Heat shield to cylinder head | ||
| M8X12 Replace screws |
tightening torque | 19 Nm |
- Replace the screw (2) .
Parts: Screw
Tighten down screw (2) .
TIGHTENING TORQUE SPECIFICATION
| Heat shield to trim strip | ||
| M6X16 Replace screw. |
Tightening torque | 8 Nm |
Follow-up work
- Refer to INSTALLING THE OIL RETURN LINE FOR THE EXHAUST 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 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 EXHAUST 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 TOP CROSS CONNECTION .
- Refer to INSTALLING UPPER CROSS CONNECTION .
- Refer to INSTALLING THE COVER FOR CENTER ENGINE COMPARTMENT .
- Refer to IF INSTALLED: INSTALLING THE COVER IN THE ENGINE COMPARTMENT AT TOP LEFT AND RIGHT (PARTIALLY REMOVED) .
- Refer to INSTALLING THE FRONT HOOD SEAL .
- Refer to INSTALLING ACOUSTIC COVER AT REAR .
- Refer to INSTALLING THE FRONT HOOD SEAL AT THE REAR .
- Refer to FILLING AND VENTING THE HIGH-TEMPERATURE COOLANT CIRCUIT .
- Refer to CHECKING ENGINE OIL LEVEL .
- Refer to INSTALLING ACOUSTIC COVER .
- Refer to INSTALLING THE COVER OF THE STEERING ASSEMBLY .
- Refer to INSTALLING THE CENTER UNDERBODY PROTECTION .
- Refer to INSTALLING UNDERBODY PROTECTION AT REAR .
- Refer to INSTALLING THE STIFFENING PLATE .
- Refer to INSTALLING FRONT UNDERBODY PROTECTION .
- Refer to TAKING HOOD OUT OF THE SERVICE POSITION .