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. 

Information 

• If the hose line of the vacuum unit is difficult to fit, moisten it with water. 

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. 

Information 

The tightening specifications for the basic engine are stored centrally.

> 1X00IN TECHNICAL VALUES

/

> 2X00IN TECHNICAL VALUES

or

> 1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES AND ASSEMBLY OVERVIEWS .

Tightening torques and assembly instructions for other assemblies (e.g. chassis, electrics, transmission or body) or for peripheral engine equipment can be found in the corresponding documents.

Information 

The pictures shown in this document may differ from the original.

1. Clean sealing faces between the turbocharger and exhaust manifold and replace the seal. -4- 
   Fig 1: Exhaust Manifold Components Location * Turbo Engine, Cylinders 5 To 8

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   Exhaust manifold on turbo engine, cylinders 5 to 8

   1	Exhaust manifold
   2	Hexagon nut, M8
   3	M8 screw
   4	Turbocharger seal
   5	Exhaust manifold seal
   A	Marking on seal visible from outside

2. Carefully move the turbocharger with lines attached into installation position. Fit new sealing rings hand-tight on the lines.
3. Screw turbocharger onto the elbow. Grease the thread of the three fastening screws -1-  (M8 x 75) with Microgleit LP 475 mounting paste (000.043.206.95, status 08/09). Tighten the screws (in two stages) to the specified torque.

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   Turbocharger fastening screws

4. Screw in oil supply line with new sealing ring on the cylinder head and tighten to the specified torque > Oil supply line  .

   > Tightening torque 35 (26 ftlb.) Nm

   1. 4.1 Then position the holding clamp and tighten the fastening screw to the specified torque -bottom arrow-  .

      > Tightening torque 10 (7.5 ftlb.) Nm

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   Oil supply line

5. Fit oil extraction line -8-  . Fit vent line (counter!) -4-  .
   Fig 2: Oil Circuit For Turbocharger Components Location With Torque Specifcation - Cylinders 5 To 8

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   Oil circuit for turbocharger, cylinders 5 to 8

   1	Oil feed line for turbocharger, cylinders 5 to 8
   2	M6 nut > Tightening torque 6.5 (5 ftlb.) Nm
   3	Holding clamp
   4	Vent line for turbocharger, cylinders 5 to 8
   5	Holding clamp
   6	Screw, M6 x 12; holder for turbocharger oil feed line to lower part of crankcase; holding clamp for oil feed line to holder > Tightening torque 10 (7.5 ftlb.) Nm
   7	Screw, M6 x 16 > Tightening torque 10 (7.5 ftlb.) Nm
   8	Oil extraction line
   9	Seal for turbocharger, cylinders 5 to 8
   10	Sealing ring
   11	Connection piece
   12	Clamp
   13	Holder for oil feed line

6. Fit coolant lines and coolant hoses > Turbocharger, cylinders 5 to 8, cooling  .
   Fig 3: Turbocharger Components Location - Cylinders 5 To 8, Cooling

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   Turbocharger, cylinders 5 to 8, cooling

   1	Coolant supply line for turbocharger, cylinders 5 to 8
   2	Hexagon nut, M6
   3	Clamp
   4	Coolant return line for turbocharger, cylinders 5 to 8
   5	Banjo bolt, M12 x 1.25; coolant supply line to turbocharger; coolant return line to turbocharger
   6	Connection for collection pipe
   7	Connection for coolant supply hose for turbocharger, cylinders 5 to 8
   8	Turbocharger, cylinders 5 - 8
   A	Direction of travel

7. Fit the hose line at the bypass flap control box -top arrow-  .

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   Connections

   NOTE: Sheared-off sealing grommet on turbocharger intake pipe 

   • Risk of damage to turbocharger 

     → A previously used intake pipe must not be re-used

     → Replace intake pipe and sealing grommet

     → Replace hose clamp

     → Coat area around sealing grommet on new intake pipe with water during fitting

8. Fit new intake pipe with new sealing grommet and hose clamp -1-  on the turbocharger. > Intake pipe 

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Intake pipe