Installing Turbocharger, Cylinder Bank 1 - 4

Information 

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

Information 

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

Information 

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

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.

Technical values for exhaust turbocharging and add-on parts,  see > 2X00IN TECHNICAL VALUES .

1. Clean sealing faces between the turbocharger and exhaust manifold and replace the seal. -3- 
   Fig 1: Exhaust Manifold Components Location - Turbo Engine, Cylinders 1 To 4

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   Exhaust manifold on turbo engine, cylinders 1 to 4

   1	Exhaust manifold
   2	Exhaust manifold seal
   3	Turbocharger seal
   4	M8 screw
   5	Hexagon nut, M8
   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. Fit the coolant line on the generator. To do this, push on the rubber hose and fit the spring band clamp. Then position the clamp and tighten the fastening screw to the specified torque.

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   Coolant line

   Fig 2: Turbocharger Components Location - Cylinders 1 To 4, Cooling

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   Turbocharger, cylinders 1 to 4, cooling

   1	Coolant return line for turbocharger, cylinders 1 to 4
   2	Coolant supply line for turbocharger, cylinders 1 to 4
   3	Coolant supply hose for turbocharger, cylinders 1 to 4
   4	Screw, M6 x 16
   5	Clamp
   6	Hexagon nut, M6
   7	Banjo bolt, M12 x 1.25; coolant supply line to turbocharger; coolant return line to turbocharger
   8	Connection for coolant supply hose for turbocharger, cylinders 1 to 4
   9	Connection for coolant return hose for turbocharger, cylinders 1 to 4
   A	Direction of travel

5. Screw in oil supply line with new sealing ring on the cylinder head -arrow-  and tighten to the specified torque.

   > Tightening torque 35 (26 ftlb.) Nm

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   Oil supply line

   1. 5.1 Then position the holding clamp and tighten the screw/nut to the specified torque -arrow-  .

      > Tightening torque 10 (7.5 ftlb.) Nm

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   Sheetmetal holder on oil supply line

   Fig 3: Oil Circuit For Turbocharger Components Location - Cylinders 1 To 4

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   Oil circuit for turbocharger, cylinders 1 to 4

   1	Vent line for turbocharger, cylinders 1 to 4; vent line to oil extraction line for turbocharger; holding clamp for vent line to collection pipe - M6 screw; holding clamp for vent line to collection pipe - M6 nut
   2	Oil supply line for turbocharger, cylinders 1 to 4; oil supply line for turbocharger to connection piece; oil feed line for turbocharger to cylinder head
   3	Connection piece
   4	Sealing ring
   5	Oil extraction line
   6	Screw, M6 x 12
   7	Screw, M6 x 16
   8	Seal for turbocharger, cylinders 1 to 4

6. Attach control line to the turbocharger. Secure the line with a new sheetmetal clip. Then attach the control line to the pressure unit > Control line  .

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   Control line

   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

7. Fit new intake pipe -1-  with new sealing grommet and hose clamp -2-  on the turbocharger.

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Intake pipe on turbocharger