Installing Turbocharger For Cylinder Bank 1-3

Information 

Specifications for wrench sizes (a/f specifications) for screw heads are described as follows:

• Torx screws: (E..) for external Torx, (T..) for internal Torx. 
• Hexagon-head bolts (internal and external hexagon): Wrench size (a/f) 

1. Pull off stoppers on oil and coolant lines one after the other, collect residual fluid and then re-insert the stoppers. Do not remove the stoppers again until immediately before fitting each line.
2. Fit exhaust manifold seal and slide the turbocharger onto the studs on the exhaust manifold.

   Always replace the metal seal on the exhaust manifold. 

   Information 

   • Replace O-rings. 
   • Grease O-rings with a light coating of Kluber Syntheso Glep (Part No.: 000.043.204.68). 
3. Fit new O-rings on all connecting lines and grease with the prescribed lubricant.
4. Fit oil pressure line on the turbocharger and fit and tighten the internal Torx screw (T30, M6 x 12).

   → Tightening torque: 10 Nm (7.5 ft. lb.) 

5. Fit upper coolant line on the turbocharger and fit and tighten the internal Torx screw (T30, M6 x 12).

   → Tightening torque: 10 Nm (7.5 ft. lb.) 

6. Fit lower coolant line on the turbocharger and fit and tighten the internal Torx screw (T30, M6 x 12).

   → Tightening torque: 10 Nm (7.5 ft. lb.) 

7. Fit vent line on the oil tank and fit and tighten the external Torx screw (E10, M6 x 12).

   → Tightening torque: 10 Nm (7.5 ft. lb.) 

8. Fit and tighten external Torx screw (E12, M8 x 16) on the turbocharger holder.

   → Tightening torque: 23 Nm (17 ft. lb.) 

9. Fit and tighten external Torx screw (E10, M6 x 12) on the vent line holder.

   → Tightening torque: 10 Nm (7.5 ft. lb.) 

10. Fit oil return line on the oil tank and fit and tighten external Torx screw (E10, M6 x 12).
    1. 10.1. Fit and tighten external Torx screw (E10, M6 x 12) on the oil return line holder.
    2. 10.2. → Tightening torque: 10 Nm (7.5 ft. lb.) 
       NOTE: Exhaust emissions temperature sensor fitted incorrectly

       • Risk of damage to components

       → Only use prescribed lubricant when installing the sensor.

       → Carefully check the thread for damage and smear the surface with Optimol MF Paste (Part No. 000.043.207.07).

11. Fit exhaust temperature sensor.
    1. 11.1. Grease thread with the prescribed lubricant.
    2. 11.2. Fit sensor on the turbocharger and fit and tighten M12 union nut (a/f 14) on the exhaust temperature sensor.

       → Tightening torque: 35 Nm (26 ft. lb.) +/-3 Nm (+/-2 ft. lb.) 

12. Fit and tighten new M8 collar nuts (a/f 12) on the exhaust manifold flange.

    → Tightening torque: 25 Nm (19 ft. lb.) 

13. Fit intake air line with cover on the turbocharger. Grease O-ring with the prescribed lubricant.
    1. 13.1. Fit new O-ring on the intake air line.
    2. 13.2. Fit cover on electronic adjuster and secure the intake air line and cover with two fastening screws (E10, M6 x 30).
    3. 13.3. Tighten the screws.

       → Tightening torque: 10 Nm (7.5 ft. lb.) 

14. Connect cable plug on the electronic adjuster.