Turbocharger: Service and Repair

AR09.40-P-6024-15A Replace Seal Between Turbocharger and Exhaust Collector








1 Clamp exhaust collector with turbocharger in vise.
Use an assistant to ensure it is clamped in at the flange (1) to the exhaust manifold.
2 Slacken bolts (2, 3).
Use an assistant to prevent the turbocharger from falling out of the vise.
3 Remove turbocharger from exhaust collector.
Pay attention to installation position of seal and position of seal tab.
4 Clean sealing surfaces on exhaust collector and turbocharger.

5 Install new seal between exhaust collector and turbocharger.
Correct position of seal tab permits correct hole pattern.
6 Screw in bolts (2, 3) finger-tight.
It must be easy to move the Turbocharger on the sealing surface to the exhaust collector in order to permit alignment
7 Reinsert turbocharger with exhaust collector.
Temporary installation serves a final assembly that is free of tension.
8 Screw turbocharger with old seal onto oil supply connection fitting.
9 Screw exhaust collector onto exhaust manifolds finger-tight using the old seal.
Fasten bolts crosswise in order to ensure an evenly level contact of the exhaust collector on both manifolds.
10 Tighten bolt (2) Nm with torque
A later displacement between exhaust collector and turbocharger leads to distortions that cause substantial engine damage
11 Loosen bolts again between exhaust collector and exhaust manifolds
12 Unscrew turbocharger again from oil supply connection fitting.
13 Carefully remove turbocharger with exhaust collector.
It is imperative to avoid touching surrounding components, since a displacement between exhaust collector and turbocharger leads to distortions that cause substantial engine damage.
14 Tighten the bolts (3) Nm between exhaust collector and turbocharger with torque.