Installing Turbocharger

WARNING: This page is about a different variant/trim than selected.

Replace sealing ring -1- at the connection point of the turbocharger and the catalytic converter.

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Turbocharger sealing ring
install turbocharger -1- .
Fit new V-band clamp -4- .

Insert new seal -5- .

Coat studs with MicroGLEIT LP 475.

Position turbocharger -1- .

Position V-band clamp -4- .

Fit turbocharger -1- flush on sealing face of catalytic converter and insert V-band clamp screw -3- by hand as far as it goes.

Information

With the use of the nut PAF.009.799, the torque at the turbocharger/exhaust manifold connection point was changed from 25 Nm (19 ftlb.) to 18 Nm (13 ftlb.).

Fit and tighten new nuts -2- .

> Tightening torque 25 Nm (19 ftlb.)

Tighten V-band clamp screw -3- .

> Tightening torque 20 Nm (15 ftlb.)

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Turbocharger
Secure the catalytic converter -1- .
Position the catalytic converter and clamping sleeve in installation position.

Tighten screws -2- on the support.

> Tightening torque 23 Nm (17 ftlb.) +/- 10 %

Tighten nuts on clamping sleeve -3- .

> Tightening torque 30 Nm (22 ftlb.) +/- 10 %

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Catalytic converter
Secure electric line -2- on turbocharger -1- .
Position electric line -2- .

Clip in clips -5 and 6- .

Connect and lock electric plug connections -3 and 4- .

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Electric line
Secure turbocharger oil supply line -1- to turbocharger -2- .
Fit new O-rings.

Position turbocharger oil supply line -1- .

Fit and tighten screw -3- .

> Tightening torque 10 Nm (7.5 ftlb.)

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Oil supply line for turbocharger
Secure turbocharger coolant liner -1- to turbocharger -2- .
Fit new O-rings.

Position turbocharger coolant lines -1- .

Fit and tighten screw -3- .

> Tightening torque 10 Nm (7.5 ftlb.)

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Coolant lines for turbocharger
Secure turbocharger oil return line -1- to turbocharger -2- .
Fit new O-rings.

Position turbocharger oil return line -1- .

Fit and tighten screw on holder -4- .

> Tightening torque 10 Nm (7.5 ftlb.)

Insert screw for oil return line flange -3- and tighten.

> Tightening torque 10 Nm (7.5 ftlb.)

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Turbocharger oil return line
Secure turbocharger vent line -1- .
Position turbocharger vent line -1- on oil return line flange -3- .

Fit and tighten screw -2- .

> Tightening torque 10 Nm (7.5 ftlb.)

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Turbocharger vent line
Secure tank vent line -1- to turbocharger -2- .
Insert holder -4- and position using tank vent line -1- .

Fit and tighten screw -3- .

> Tightening torque 10 Nm (7.5 ftlb.)

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Tank vent line
install intake pipe -1- .
Position intake pipe -1- .

Fit new V-band clamp.

Tighten V-band clamp screw -2- .

> Tightening torque 5.5 Nm (4 ftlb.) +/- 0.2 Nm (0.1 ftlb.)

Tighten screw-type clamp -3- .

> Tightening torque 2.5 Nm (1.75 ftlb.) + 0.5 Nm (0.3 ftlb.)

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Air intake pipe
Right side only:
Secure vent line -1- to charge air pipe -2- .

Position vent line -1- .

Connect and lock plug-in coupling -3- .

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Vent line on charge air pipe
Secure pressure hose -1- to turbocharger -2- .
Position pressure hose -1- on turbocharger connection piece.

Tighten screw-type clamp -3- .

> Tightening torque 5.5 Nm (4 ftlb.) +/- 0.2 Nm (0.1 ftlb.)

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Pressure hose