Installing Turbocharger, Cylinder Bank 1 - 4: Notes

Information 

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

1. Clean sealing faces between the turbocharger and exhaust manifold and replace the seal. -3- 
   Fig 1: Locating Exhaust Manifold On Turbo Engine M48/51 (Cylinders 1 To 4)

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   1. Exhaust manifold
   2. Exhaust manifold seal
   3. Turbocharger seal
   4. Screw, M8 x 75
   5. M8 hexagon nut
   1. Marking on seal visible from outside

   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. 
2. Carefully move the turbocharger with lines attached into installation position. Fit new sealing rings hand-tight on the lines.

   Information 

   • The 3 fastening screws of the turbocharger may only be greased on the thread, but not below the head. 
3. Screw the turbocharger onto the manifold. Grease the thread of the three fastening screws (M8 x 75) with Microgleit LP 475 mounting paste/000.043.206.95 (status 08/07). Tighten the screws to the specified torque (in two stages). → Initial tightening: 23 Nm (17 ft lbs.);  then → Final tightening: 30 Nm (22 ft lbs.) 
   Fig 2: Locating Turbocharger Fastening Screws

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4. Install the turbocharger support. To do this, tighten the two upper fastening screws (M8 x 20) on the cylinder head to the specified torque. Then insert the lower fastening screw from the front, replace nut and tighten to the specified torque.
   Fig 3: Locating Turbocharger Support

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   Fig 4: Identifying Turbocharger (Cylinders 1 To 4)

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   1. Turbocharger, cylinders 1 to 4
   2. Hexagon nut, M8 → Tightening torque: 30 Nm (22 ft lbs.) 
   3. Screw, M8 x 20 → Tightening torque: 23 Nm (17 ft lbs.) 
   4. Turbocharger bracket
   5. Screw M8 x 40 → Tightening torque: 30 Nm (22 ft lbs.) 
   6. Stud
5. 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. Tightening torque: 10 Nm (7.5 ft lbs.) 
   Fig 5: Locating Coolant Line

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   Fig 6: Identifying Turbocharger (Cylinders 1 To 4 - Cooling)

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   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 ft lbs.) 
   5. Clamp
   6. Hexagon nut, M6 → Tightening torque: 8.5 Nm (6.0 ft lbs.) 
   7. Banjo bolt, M12 x 1.25; coolant supply line to turbocharger → Tightening torque: 35 Nm (26 ft lbs.)  ; coolant return line to turbocharger. Tightening torque: 35 Nm (26 ft lbs.) 
   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
6. Screw in oil supply line with new sealing ring on the cylinder head and tighten to the specified torque. → Tightening torque: 35 Nm (26 ft lbs.)  Then position the holding clamp and tighten the fastening screw to the specified torque. → Tightening torque: 10 Nm (7.5 ft lbs.) 
   Fig 7: Locating Oil Supply Line

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   Fig 8: Locating sheet metal Holder On Oil Supply Line

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7. Fit the oil extraction line between the turbocharger and oil guide housing -5-  . Replace seals.
   Fig 9: Identifying Oil Circuit For Turbocharger (Cylinders 1 To 4)

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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 ft lbs.)  ; holding clamp on vent line to collection pipe, M6 screw → Tightening torque: 10 Nm (7.5 ft lbs.)  ; holding clamp on vent line to collection pipe, M6 nut → Tightening torque: 6.5 Nm (5.0 ft lbs.) 
   2. Turbocharger oil supply line for cylinders 1 to 4; turbocharger oil supply line to connection piece → Tightening torque: 40 Nm (30 ft lbs.)  ; turbocharger oil supply line to cylinder head → Tightening torque: 35 Nm (26 ft lbs.) 
   3. Connection piece → Tightening torque: 45 Nm (33 ft lbs.) 
   4. Sealing ring
   5. Oil extraction line
   6. Screw, M6 x 12 → Tightening torque: 10 Nm (7.5 ft lbs.) 
   7. Screw, M6 x 16 → Tightening torque: 10 Nm (7.5 ft lbs.) 
   8. Seal for turbocharger, cylinders 1 to 4

   Information 

   • If the hose line of the vacuum unit is difficult to fit, moisten it with water. 
8. Attach control line to the turbocharger. Secure the line with a new sheet metal clip. Then attach the control line to the pressure unit. .
   Fig 10: Locating Control Line

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9. Fit the intake manifold on the turbocharger -1-  .
   Fig 11: Identifying Intake Manifold On Turbocharger

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