Group 21, Turbocharging

Information 

Tighten screw-type clamps for securing pressure and intake pipes and pressure and suction hoses to charge-air cooler and turbocharger to → Tightening torque: 5.5 Nm (4 ftlb.)  .

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 → Tightening torque: 10 Nm (7.5 ftlb.) 
5. Clip
6. Hexagon nut, M6 → Tightening torque: 8.5 Nm (6 ftlb.) 
7. Banjo bolt, M12 x 1.25; coolant supply line to turbocharger → Tightening torque: 30 Nm (22 ftlb.)  ; coolant return line to turbocharger → Tightening torque: 30 Nm (22 ftlb.) 
8. Connection for coolant supply hose for turbocharger, cylinders 1 to 4
9. Connection for coolant return hose for turbocharger, cylinders 1 to 4

1. Direction of travel
Fig 1: Identifying Coolant Return Line For Turbocharger
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1. Coolant supply line for turbocharger, cylinders 5 to 8
2. Hexagon nut, M6 → Tightening torque: 8.5 Nm (6 ftlb.) 
3. Clip
4. Coolant return line for turbocharger, cylinders 5 to 8
5. Banjo bolt, M12 x 1.25; coolant supply line to turbocharger → Tightening torque: 30 Nm (22 ftlb.)  ; coolant return line to turbocharger → Tightening torque: 30 Nm (22 ftlb.) 
6. Collection pipe connection → Tightening torque: 35 Nm (26 ftlb.) 
7. Connection for coolant supply hose for turbocharger, cylinders 5 to 8
8. Turbocharger, cylinders 5 to 8

1. Direction of travel
Fig 2: Identifying Coolant Return Line For Turbocharger
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1. Turbocharger vent line for cylinders 1 to 4; vent line to turbocharger oil extraction line → Tightening torque: 35 Nm (26 ftlb.)  ; holding clamp on vent line to collection pipe, M6 screw → Tightening torque: 10 Nm (7.5 ftlb.)  ; holding clamp on vent line to collection pipe, M6 nut → Tightening torque: 6.5 Nm (5 ftlb.) 
2. Turbocharger oil feed line for cylinders 1 to 4; turbocharger oil feed line to connection piece → Tightening torque: 40 Nm (30 ftlb.)  ; turbocharger oil feed line to cylinder head → Tightening torque: 35 Nm (26 ftlb.) 
3. Connection piece → Tightening torque: 45 Nm (33 ftlb.) 
4. Sealing ring
5. Oil extraction line
6. Screw, M6 x 12 → Tightening torque: 10 Nm (7.5 ftlb.) 
7. Screw, M6 x 16 → Tightening torque: 10 Nm (7.5 ftlb.) 
8. Seal for turbocharger, cylinders 1 to 4
Fig 3: Identifying Turbocharger Vent Line For Cylinders (1-4)
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1. Oil feed line for turbocharger, cylinders 5 to 8
2. Nut, M6 → Tightening torque: 6.5 Nm (5 ftlb.) 
3. Holding clamp
4. Vent line on turbocharger for cylinders 5 to 8 → Tightening torque: 10 Nm (7.5 ftlb.) 
5. Holding clamp
6. Screw, M6 x 12; turbocharger oil feed line holder to lower part of crankcase → Tightening torque: 10 Nm (7.5 ftlb.)  ; holding clamp for oil feed line to holder → Tightening torque: 10 Nm (7.5 ftlb.) 
7. Screw, M6 x 16 → Tightening torque: 10 Nm (7.5 ftlb.) 
8. Oil extraction line
9. Seal for turbocharger, cylinders 5 to 8
10. Sealing ring
11. Connection piece → Tightening torque: 45 Nm (33 ftlb.) 
12. Clip
13. Holder for oil feed line

Fig 4: Identifying Turbocharger Vent Line For Cylinders (5-8)

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1. Turbocharger, cylinders 1 to 4

1. 4  - Turbocharger bracket (no longer used)
2. 6  - Stud
Fig 5: Identifying Turbocharger (Cylinders 1 To 4)
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1. Turbocharger, cylinders 5 to 8
2. Turbocharger bracket (no longer used)

1. 6  - Stud
Fig 6: Identifying Turbocharger (Cylinders 5 To 8)
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1. Pressure line, boost pressure line
2. Hose clamp
3. Cycle valve
4. Combination holder
5. Holder to timing-case cover → Initial tightening: 4 Nm (3 ftlb.)  and → Final tightening: 90° 
6. Control line
7. Control line
8. Hose holder
Fig 7: Identifying Boost Pressure, Wastegate And Hose Clamp
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1. Pressure line
2. Vacuum line
3. Hose clamp
4. Screw, M6 x 12 → Tightening torque: 10 Nm (7.5 ftlb.) 
5. Holder
6. Rubber element
7. Electric change-over valve
8. Control line

1. View A; connection of pressure line to intake-air distributor
Fig 8: Identifying Boost Pressure And Wastegate 2
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