Removal and Replacement

Removing And Installing Turbocharger

Technical values







Information

Component overview







Preliminary work
1. Remove rear apron.
2. Remove charge air cooler.
3. Remove rear silencer.

Removing turbocharger

WARNING:
Coolant is corrosive and hazardous to health.
- Risk of skin and eye irritation.

- Wear protective gloves and goggles.
- If you come into contact with coolant, wash off immediately with plenty of warm water.

CAUTION:
Assembly of deformed heat shields.
- Damage will be caused through heat build up if deformed heat shields are installed.

- Check heat shields for deformation, fixing of the aluminium braided cord, tears and missing or damaged fixing tabs.
- Damaged or distorted heat shields must be straightened or replaced.






1. Unscrew Torx screw (M6 x 16) -5- on oil return line holding clamp -6- and cable holder for exhaust temperature sensor -7-.

DANGER:
Parts of the exhaust system become extremely hot.
- Danger of burns
- Permanent scarring of the skin

- Do not begin work until the exhaust system has cooled down completely.
- If it is imperative that you work on the hot exhaust system, ensure that you wear fire-resistant and heat-resistant protective gear.

1.1. Remove exhaust temperature sensor -4- on turbocharger by loosening and sliding back the M12 union nut (a/f 14) -3- on the exhaust temperature sensor.

NOTE:
Mixing fluids
- Risk of damage to components

- Close off all openings immediately after exposing them (with adhesive tape, suitable stoppers).

1.2. Unscrew Torx screw (M6 x 12) -1- on oil return line -2-. Pull off line and collect escaping engine oil. Close off oil extraction line and opening on oil tank with stoppers.

2. Remove oil and coolant lines on turbocharger.
3. Pull off cable plug on electronic adjuster for turbocharger.







4. Loosen M6 collar nut -1- on intake manifold heat shield.
4.1. Unscrew two Torx screws (M6 x 20) -arrow- on the intake manifold, pull off intake manifold and remove heat shield.

5. Pull off hose on control box for ambient air valve.







6. Remove three M8 lock nuts -1- on the turbocharger/exhaust manifold flange.
6.1. Replace lock nuts.

7. Remove Torx screw (M8 x 16) on turbocharger holder and take off turbocharger.
8. Clean sealing faces on the turbocharger and exhaust manifold.
8.1. Clean studs with a steel brush. Replace defective M8 studs if necessary.

9. Replace all O-rings and grease them with Kluber Syntheso Glep.

Removing turbocharger for cylinder 4-6

WARNING:
Coolant is corrosive and hazardous to health.
- Risk of skin and eye irritation.

- Wear protective gloves and goggles.
- If you come into contact with coolant, wash off immediately with plenty of warm water.

CAUTION:
Assembly of deformed heat shields.
- Damage will be caused through heat build up if deformed heat shields are installed.

- Check heat shields for deformation, fixing of the aluminium braided cord, tears and missing or damaged fixing tabs.
- Damaged or distorted heat shields must be straightened or replaced.

NOTE:
Mixing fluids
- Risk of damage to components

- Close off all openings immediately after exposing them (with adhesive tape, suitable stoppers).

1. Remove Torx screw (M6 x 16) on oil extraction line clamp.

DANGER:
Parts of the exhaust system become extremely hot.
- Danger of burns
- Permanent scarring of the skin

- Do not begin work until the exhaust system has cooled down completely.
- If it is imperative that you work on the hot exhaust system, ensure that you wear fire-resistant and heat-resistant protective gear.







2. Remove exhaust temperature sensor -3- on the turbocharger. To do this, loosen M12 union nut (a/f 14) -4- and slide it back.
2.1. Unscrew Torx screw (M6 x 12) -1- on the oil return line -2-, pull off line and collect emerging engine oil.

3. Remove oil and coolant lines on turbocharger.
4. Pull off hose on control box for ambient air valve.







5. Remove two Torx screws (M6 x 20) -arrow- on the intake pipe and pull off intake pipe.
5.1. Pull off cable plugs -1-.

6. Remove three M8 lock nuts on the turbocharger/exhaust manifold flange.
6.1. Replace lock nuts.

7. Remove screw (M8 x 16) on turbocharger holder and take off turbocharger.
8. Clean sealing faces on the turbocharger and exhaust manifold.
8.1. Clean studs with a steel brush. Replace defective M8 studs if necessary.

9. Replace all O-rings and grease them with Kluber Syntheso Glep.

Installing turbocharger

Installing turbocharger for cylinder 1-3

WARNING:
Coolant is corrosive and hazardous to health.
- Risk of skin and eye irritation.

- Wear protective gloves and goggles.
- If you come into contact with coolant, wash off immediately with plenty of warm water.

CAUTION:
Assembly of deformed heat shields.
- Damage will be caused through heat build up if deformed heat shields are installed.

- Check heat shields for deformation, fixing of the aluminium braided cord, tears and missing or damaged fixing tabs.
- Damaged or distorted heat shields must be straightened or replaced.

NOTE:
Mixing fluids
- Risk of damage to components

- Close off all openings immediately after exposing them (with adhesive tape, suitable stoppers).

WARNING:
Coolant is corrosive and hazardous to health.
- Risk of skin and eye irritation.

- Wear protective gloves and goggles.
- If you come into contact with coolant, wash off immediately with plenty of warm water.

NOTE:
Mixing fluids
- Risk of damage to components

- Close off all openings immediately after exposing them (with adhesive tape, suitable stoppers).

1. Pull off stoppers on oil and coolant lines one after the other, collect residual fluid and then re-insert the stoppers.







2. Fit new seal on the turbocharger/exhaust manifold flange, insert turbocharger and fix in place on the flange using three new M8 lock nuts -1-.
3. Screw in Torx screw (M8 x 16) on turbocharger holder.

INFORMATION:
- Replace O-rings.
- Grease O-rings with a light coating of Kluber Syntheso Glep (Part No.: 000.043.204.68).

4. Fit oil and coolant lines with new O-rings on the turbocharger. - Tightening torque: 10 Nm (7.5 ftlb.)







5. Remove stopper on oil return line and turbocharger oil tank and connect line -2-.
5.1. Fit and tighten Torx screws (M6 x 12) -1-. - Tightening torque: 10 Nm (7.5 ftlb.)

CAUTION:
Exhaust emissions temperature sensor fitted incorrectly
- Risk of damage to components

- Only use prescribed lubricant when installing the sensor.
- Carefully check thread for damage and coat the surface with Optimol MF Paste.

5.2. Coat the surface of the thread and the front of the exhaust temperature sensor with Optimol MF Paste.
5.3. Fit exhaust temperature sensor -4- on turbocharger and insert and tighten M12 union nut -3-. - Tightening torque: 35 Nm (26 ftlb.)±3 Nm (±2 ftlb.)
5.4. Fit and tighten Torx screw (M6 x 16) -5- on oil extraction line clamp -6-. Also secure cable holder -7- for exhaust temperature sensor at the same time. - Tightening torque: 10 Nm (7.5 ftlb.)







6. Tighten new M8 lock nuts -1- on the turbocharger/exhaust manifold flange and Torx screw (M8 x 16) on the turbocharger holder. - Tightening torque: 25 Nm (19 ftlb.) - Tightening torque: 23 Nm (17 ftlb.)
7. Fit intake pipe with heat shield on turbocharger.
7.1. Replace O-ring and grease with Kluber Syntheso Glep. Fit intake pipe on turbocharger.







7.2. Fit and tighten two Torx screws (M6 x 20) -arrow-. - Tightening torque: 10 Nm (7.5 ftlb.) - Tightening torque: 10 Nm (7.5 ftlb.)

8. Connect cable plug to electronic adjuster. The plug must lock with an audible click.
9. Connect hose to control box for ambient air valve.

Installing turbocharger for cylinder 4-6

CAUTION:
Assembly of deformed heat shields.
- Damage will be caused through heat build up if deformed heat shields are installed.

- Check heat shields for deformation, fixing of the aluminium braided cord, tears and missing or damaged fixing tabs.
- Damaged or distorted heat shields must be straightened or replaced.

CAUTION:
Exhaust emissions temperature sensor fitted incorrectly
- Risk of damage to components

- Only use prescribed lubricant when installing the sensor.
- Carefully check thread for damage and coat the surface with Optimol MF Paste.

WARNING:
Coolant is corrosive and hazardous to health.
- Risk of skin and eye irritation.

- Wear protective gloves and goggles.
- If you come into contact with coolant, wash off immediately with plenty of warm water.

NOTE:
Mixing fluids
- Risk of damage to components

- Close off all openings immediately after exposing them (with adhesive tape, suitable stoppers).

1. Pull off stoppers on oil and coolant lines one after the other, collect residual fluid and then re-insert the stoppers.
2. Fit new seal on the turbocharger/exhaust manifold flange, insert turbocharger and fix in place on the flange using three new M8 lock nuts.
3. Screw in Torx screw (M8 x 16) on turbocharger holder.

INFORMATION:
- Replace O-rings.
- Grease O-rings with a light coating of Kluber Syntheso Glep (Part No.: 000.043.204.68).

4. Fit oil and coolant lines with new O-rings on the turbocharger. - Tightening torque: 10 Nm (7.5 ftlb.)
5. Remove stopper on oil return line and turbocharger oil tank and connect line -2-.







5.1. Fit and tighten Torx screws (M6 x 12) -1-. - Tightening torque: 10 Nm (7.5 ftlb.)

CAUTION:
Exhaust emissions temperature sensor fitted incorrectly
- Risk of damage to components

- Only use prescribed lubricant when installing the sensor.
- Carefully check thread for damage and coat the surface with Optimol MF Paste.

5.2. Coat the surface of the thread and the front of the exhaust temperature sensor with Optimol MF Paste.
5.3. Fit exhaust temperature sensor -4- on turbocharger and insert and tighten M12 union nut -3-. - Tightening torque: 35 Nm (26 ftlb.)±3 Nm (±2 ftlb.)
5.4. Fit and tighten Torx screw (M6 x 16) -5- on oil extraction line clamp -6-. Also secure cable holder -7- for exhaust temperature sensor at the same time. - Tightening torque: 10 Nm (7.5 ftlb.)

6. Tighten new M8 lock nuts -1- on the turbocharger/exhaust manifold flange and Torx screw (M8 x 16) on the turbocharger holder. - Tightening torque: 25 Nm (19 ftlb.) - Tightening torque: 23 Nm (17 ftlb.)
7. Fit intake pipe on turbocharger.
7.1. Replace O-ring and grease with Kluber Syntheso Glep. Fit intake pipe on turbocharger.







7.2. Fit and tighten two Torx screws (M6 x 20) -arrows-. - Tightening torque: 10 Nm (7.5 ftlb.)
7.3. Connect cable plug to electronic adjuster for turbocharger -1- until the cable plug locks with an audible click.

8. Connect hose to control box for ambient air valve.

Subsequent work
1. Install rear silencer.
2. Install charge air cooler.
3. Fill in coolant up to the Max. marking on the coolant reservoir.
4. Check engine-oil level and top up with new engine oil if necessary.
5. Carry out a test drive. Check the coolant and oil level and correct it if necessary.