Installing Turbocharger, Cylinder Bank 5 - 8

Information 

Seals and sealing rings on the lines must always be replaced.

Information 

• The 3 fastening screws of the turbocharger may only be greased on the thread, but not below the head. 

1. Clean sealing faces between the turbocharger and exhaust manifold and replace the seal. -4- 
   Fig 1: Identifying Exhaust Manifold On Turbo Engine M48/51 (Cylinders 5 To 8)

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   1. Exhaust manifold
   2. M8 hexagon nut
   3. Screw, M8 x 75
   4. Turbocharger seal
   5. Exhaust manifold seal
   1. Marking on seal visible from outside

   Information 

   • The turbocharger with lines attached is held in one hand. Use your other hand to fit the lines on the engine first, then secure the turbocharger hand-tight to the exhaust manifold with three screws. 
2. Carefully move the turbocharger with lines attached into installation position. Fit new sealing rings hand-tight on the lines.

   Information 

   • The 3 fastening screws of the turbocharger may only be greased on the thread, but not below the head. 
3. Screw the turbocharger onto the manifold. Grease the thread of the three fastening screws (M8 x 75) with Microgleit LP 475 mounting paste/000.043.206.95 (status 08/07). Tighten the screws to the specified torque (in two stages). → Initial tightening: 23 Nm (17 ft lbs.)  ; then → Final tightening: 30 Nm (22 ft lbs.) 
   Fig 2: Locating Turbocharger Fastening Screws

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4. Install the turbocharger support. To do this, tighten the two upper fastening screws (M8 x 20) on the cylinder head to the specified torque. Then insert the lower fastening screw from the front, replace nut and tighten to the specified torque.
   Fig 3: Locating Turbocharger Support

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   Fig 4: Identifying Turbocharger (Cylinders 5 To 8)

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   1. Turbocharger, cylinders 5 to 8
   2. Turbocharger bracket
   3. Screw, M8 x 20 → Tightening torque: 23 Nm (17 ft lbs.) 
   4. Screw, M8 x 40 → Tightening torque: 30 Nm (22 ft lbs.) 
   5. Hexagon nut, M8 → Tightening torque: 30 Nm (22 ft lbs.) 
   6. Stud
5. Screw in oil supply line with new sealing ring on the cylinder head and tighten to the specified torque. Tightening torque: 35 Nm (26 ft lbs.)  Then position the holding clamp and tighten the fastening screw to the specified torque. → Tightening torque: 10 Nm (7.5 ft lbs.) 
   Fig 5: Locating Oil Supply Line

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6. Fit oil extraction line -8-  . Fit vent line (counter!) -4-  .
   Fig 6: Identifying Oil Circuit For Turbocharger (Cylinders 5 To 8)

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   1. Oil supply line for turbocharger, cylinders 5 to 8
   2. Nut, M6 → Tightening torque: 6.5 Nm (5.0 ft lbs.) 
   3. Holding clamp
   4. Turbocharger vent line for cylinders 5 to 8 → Tightening torque: 10 Nm (7.5 ft lbs.) 
   5. Holding clamp
   6. Screw, M6 x 12; turbocharger oil supply line holder to lower part of crankcase → Tightening torque: 10 Nm (7.5 ft lbs.);  holding clamp for oil supply line to holder → Tightening torque: 10 Nm (7.5 ft lbs.) 
   7. Screw, M6 x 16 → Tightening torque: 10 Nm (7.5 ft lbs.) 
   8. Oil extraction line
   9. Turbocharger seal, cylinders 5 to 8
   10. Sealing ring
   11. Connection piece
   12. Clamp
   13. Holder for oil supply line
7. Fit coolant lines and coolant hoses → .
   Fig 7: Identifying Turbocharger (Cylinders 5 To 8 - Cooling)

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   1. Coolant supply line for turbocharger, cylinders 5 to 8
   2. Hexagon nut, M6 → Tightening torque: 8.5 Nm (6.0 ft lbs.) 
   3. Clamp
   4. Coolant return line for turbocharger, cylinders 5 to 8
   5. Banjo bolt, M12 x 1.25; coolant supply line to turbocharger → Tightening torque: 35 Nm (26 ft lbs.)  ; coolant return line to turbocharger. Tightening torque: 35 Nm (26 ft lbs.) 
   6. Collection pipe connection → Tightening torque: 35 Nm (26 ft lbs.) 
   7. Connection for coolant supply hose for turbocharger, cylinders 5 to 8
   8. Turbocharger, cylinders 5 to 8
   1. Direction of travel

   Information 

   • If the hose line of the vacuum unit is difficult to fit, moisten it with water. 
8. Fit the hose line at the bypass valve control box -top arrow-  .
   Fig 8: Locating Hose Line At Bypass Valve Control Box Connections

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9. Fit the right intake manifold on the turbocharger.
   Fig 9: Identifying Intake Manifold

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