Turbocharger with Exhaust Manifold and Attachments Assembly Overview
Turbocharger with Exhaust Manifold and Attachments Assembly Overview
CAUTION!
• Follow the safety precautions when working on the charge air system and turbocharger. Refer to --> [ Safety Precautions ] Safety Precautions.
• Observe rules for cleanliness. Refer to --> [ Clean Working Conditions ] Clean Working Conditions.
Always follow these instructions before and during work.
• Refer to --> [ Particulate Filter with NOx Absorption Catalytic Converter Assembly Overview ] Particulate Filter with NOx Absorption Catalytic Converter Assembly Overview.
1 8 Nm
2 Warm Air Collector Plate
• To warm air intake connecting hose on the air filter --> [ 12 Connecting Hose ] Air Filter Assembly Overview
3 10 Nm
4 Oil Supply Line
• Do not change angles of the oil supply line
• Install without tension
• From oil filter bracket --> [ 6 Oil Supply Line, 22 Nm ] Service and Repair
• Removing and installing, refer to --> [ Oil Supply Line to Turbocharger ] Service and Repair
• Before installing, check oil supply line for clear passage
• Fill with engine oil before installing turbocharger oil supply line on the connections
• Tightening specification: 22 Nm
5 Vacuum Hose
• Make sure it is seated correctly and is routed without kinks
• To wastegate bypass regulator valve (N75)
• Connection diagram for vacuum hoses --> [ Vacuum Hose Connection Diagram ] [1][2]Diagrams
6 Vacuum Diaphragm
• With charge pressure actuator position sensor (G581)
• Unit with turbocharger and exhaust manifold (cannot be replaced separately)
7 Heat Shield
• Replace if damaged
8 Heat Shield
9 Bracket
• For wiring harness
10 Seal
• Replace
11 Securing Clamp
• Replace
• Note installation position --> [ Clamp Installation Position Between the Particulate Filter and Turbocharger ] Particulate Filter with NOx Absorption Catalytic Converter Assembly Overview
• Tightening specification: 7 Nm
12 To Particulate Filter
• --> [ 27 Particle Filter ] Particulate Filter with NOx Absorption Catalytic Converter Assembly Overview
13 Gasket
• Replace
• Note installation position
14 Turbocharger
• Unit with exhaust manifold and vacuum diaphragm (cannot be replaced separately)
• Removing and installing, refer to --> [ Turbocharger with Exhaust Manifold ] Turbocharger with Exhaust Manifold.
15 23 Nm
• Replace
• Lubricate exhaust manifold stud bolts with hot bolt paste (G 052 112 A3).
16 Heat Shield
17 Stud Bolt
• Tightening specification: 20 Nm
18 23 Nm
• Installed on stud bolt --> [ (item 17) Stud Bolt ] on the turbocharger
19 23 Nm
• Secure on exhaust manifold with heat shield --> [ 16 Heat Shield ]
20 Control Wire
• Do not change the angles of the control line
• Between EGR housing --> [ 16 Housing ] Service and Repair and exhaust pressure sensor 2 --> [ 1 ] Particulate Filter with NOx Absorption Catalytic Converter Assembly Overview
• To loosen at housing, remove exhaust gas recirculation filter --> [ 9 Filter ] Service and Repair
• Install without tension
• Tightening specification: 23 Nm
21 Filter
• For EGR system
• --> [ 9 Filter ] Service and Repair
22 Brace
• For turbocharger
23 Seal
• Replace
24 Banjo Bolt
• Replace
• Tightening specification: 60 Nm
25 O-Ring
• Replace
26 Oil Return Line
• Install without tension
27 15 Nm
28 Pulsation Damper
• To hot side connecting hose, upper --> [ (item 13) Connecting Hose ] Charge Air Cooler Components Assembly Overview
29 Connecting Pipe
CAUTION!
Make sure the connecting pipe decoupling element does not bend or stretch. Cracks could develop.
• Between exhaust manifold and intake manifold --> [ 5 Connecting Pipe ] Intake Manifold With Attachments Assembly Overview
• Replace
• Install without tension
30 20 Nm
• Lubricate exhaust manifold stud bolts with hot bolt paste (G 052 112 A3).
31 Connecting Pipe
• From exhaust gas recirculation housing --> [ 2 Connecting Pipe ] Service and Repair
• To remove and install, also loosen connections --> [ 33 Connecting Piece ] on the turbocharger
32 Seal
• Replace if damaged
33 Connecting Piece
34 O-Ring
• Replace if damaged
35 Intake Scoop
• Ensure seated tightly
• Clean if contaminated
• From intake hose on air filter --> [ 1 Intake Tube ] Air Filter Assembly Overview
• With PCV heating element
Removing
- Disconnect crankcase ventilation hose at intake scoop.
• The crankcase ventilation hose is destroyed when it is removed.
- Remove bolt --> [ 36 8 Nm ].
- Rotate intake scoop clockwise and remove it from connections --> [ 33 Connecting Piece ].
Installing
- Clean intake scoop. It must be free of oil and grease.
- Slide intake scoop onto connections --> [ 33 Connecting Piece ] and rotate it counterclockwise until it engages on connections.
- Tighten bolt --> [ 36 8 Nm ].
- Install a new crankcase ventilation hose.
36 8 Nm
37 Exhaust Gas Temperature Sensor 1 (G235), 45 Nm
• Mark installation position before removing
• Only lubricate threads with hot bolt paste (G 052 112 A3)