Installing Turbocharger On Cylinders 4-6

Information 

Replace sealing rings, seals and O-rings.

Information 

Before installing  the new turbocharger, remove all  the stoppers  on the turbocharger -1 and 2-  .

Ensure, in particular, that the conical rubber stopper on the connecting flange for the oil line -2-  is also removed.

In some cases, the rubber stopper, as shown in -bottom, 2-  , may be pressed slightly into the bore when the turbocharger is supplied. As a result, it is not immediately visible from the outside - particularly when fitting the oil line. Always remove rubber stoppers before fitting the oil line  .

Fig 1: Identifying Stoppers On Turbocharger

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• Item 1: Plastic stoppers (not always fitted - depends on the type of packaging in which the turbocharger is supplied) -1-  .
• Item 2: Rubber stopper (always fitted) -2-  .

1. Clean sealing faces between the exhaust manifold -1-  cylinder head and replace seal -2-  .
2. Fit turbocharger with exhaust manifold -1-  on cylinder head for cylinders 4 - 6.
3. Use new fastening nuts -3-  .
   Fig 2: Identifying Exhaust Manifold/Turbocharger Related Components (Cylinders 4-6)

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4. Tighten new fastening nuts to the specified tightening torque in the sequence -1-9-  .
   Fig 3: Identifying Exhaust Manifold/Turbocharger Nut Tightening Sequence

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5. Further installation is performed in reverse order.