Turbocharger and Exhaust Manifold with Attachments Overview
Turbocharger and Exhaust Manifold with Attachments Overview
• Follow the safety precautions when working on the charge air system and turbocharger. Refer to => [ Safety Precautions ] Safety Precautions.
• Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
Always follow these instructions before and during work.
• Particulate filter with NOx reduction catalyst overview. Refer to one of the following:
• Engine code CBEA, refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter with NOx Reduction Catalytic Converter Overview.
• Engine code CJAA, refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter with NOx Reduction Catalytic Converter Overview.
1 Bolt
• 8 Nm
2 Warm Air Collector Plate
• To the warm air connecting hose - item 12 - in => [ Air Filter Housing Overview ] Air Filter Housing Overview to the air filter.
3 Bolt
• 10 Nm
4 Oil Supply Line
• 22 Nm
• Do not change the angles of the oil supply line.
• Install without tension.
• From the oil filter bracket, see - item 6 - in => [ Oil Filter Bracket and Oil Cooler Overview ] Oil Filter Bracket and Oil Cooler Overview.
• Removing and installing, refer to => [ Oil Supply Line to Turbocharger ] Service and Repair.
• Before installing, check the oil supply line for clear passage.
• Fill with engine oil before installing the turbocharger oil supply line to the connections.
5 Vacuum Hose
• Make sure the hose is seated correctly and is routed without kinks.
• To the wastegate bypass regulator valve (N75).
• Vacuum hose connection diagram. Refer to => [ Vacuum Hose Connection Diagram ] [1][2]Diagrams.
6 Vacuum Diaphragm
• With the 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 the wiring harness.
10 Seal
• Always replace
11 Clamp
• 7 Nm
• Always replace
• Note the installed position, refer to one of the following:
Engine code CBEA, refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter with NOx Reduction Catalytic Converter Overview.
Engine code CJAA, refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter with NOx Reduction Catalytic Converter Overview.
12 to the Particulate Filter
• Refer to one of the following:
Engine code CBEA, refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter with NOx Reduction Catalytic Converter Overview.
Engine code CJAA, refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter with NOx Reduction Catalytic Converter Overview.
13 Gasket
• Always replace
• Note the installed position.
14 Turbocharger
• Unit with the exhaust manifold and vacuum diaphragm (cannot be replaced separately).
• Removing and installing, refer to => [ Turbocharger and Exhaust Manifold ] Turbocharger and Exhaust Manifold.
15 Nut
• 23 Nm
• Always replace
• Coat the studs on the exhaust manifold with hot bolt paste (G 052 112 A3).
16 Heat Shield
17 Stud Bolt
• 20 Nm
18 Nut
• 23 Nm
• Installed on the stud bolt - item 17 - on the turbocharger.
19 Nut
• 23 Nm
• To the exhaust manifold for the heat shield - item 16 -.
20 Control Line
• 23 Nm
• Do not change the angles of the control line.
• Between the Exhaust Gas Recirculation (EGR) housing - item 16 - in => [ Exhaust Gas Recirculation System Component Overview ] Service and Repair and the exhaust pressure sensor 2 (G451) one of the following:
Engine code CBEA, see - item 1 - in => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter with NOx Reduction Catalytic Converter Overview.
Engine code CJAA, see - item 1 - in => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter with NOx Reduction Catalytic Converter Overview.
• To loosen at the housing - item 16 - in => [ Exhaust Gas Recirculation System Component Overview ] Service and Repair remove the EGR filter - item 9 - in => [ Exhaust Gas Recirculation System Component Overview ] Service and Repair.
• Install without tension
21 Filter
• For Exhaust Gas Recirculation (EGR) system
• See - item 9 - in => [ Exhaust Gas Recirculation System Component Overview ] Service and Repair.
22 Brace
• For the turbocharger
23 Seal
• Always replace
24 Banjo Bolt
• 60 Nm
• Always replace
25 O-ring
• Always replace
26 Oil Return Line
• Install without tension
27 Bolt
• 15 Nm
28 Damper
• To the hot side upper charge air hose - item 13 - in => [ Charge Air Cooler Component Overview ] Service and Repair.
29 Connecting Pipe
Make sure the connecting pipe decoupling element does not bend or stretch. Cracks could develop.
• Between the exhaust manifold and intake manifold, see - item 5 - in => [ Intake Manifold and Attachments Overview ] Intake Manifold and Attachments Overview.
• Always replace
• Install without tension
30 Nut
• 20 Nm
• Coat the stud on the exhaust manifold with hot bolt paste (G 052 112 A3).
31 Connecting Pipe
• From the EGR housing, see - item 2 - in => [ Exhaust Gas Recirculation System Component Overview ] Service and Repair.
• To remove and install, also loosen the connecting piece - item 33 - on the turbocharger.
32 Seal
• Replace if damaged
33 Connecting Piece
34 O-ring
• Replace if damaged
35 Intake Scoop
• Ensure the scoop is seated securely.
• Clean if there are contaminants
• To he intake tube - item 1 - in => [ Air Filter Housing Overview ] Air Filter Housing Overview from the air filter housing.
• With the Positive Crankcase Ventilation (PCV) heating element.
Removing:
- Disconnect the crankcase ventilation hose from the intake scoop.
• The crankcase ventilation hose is destroyed when it is removed.
- Remove the bolt - item 36 -.
- Rotate the intake scoop clockwise and remove it from the connecting piece - item 33 -.
Installing:
- Clean the intake scoop. It must be free of oil and grease.
- Slide the intake scoop onto the connecting piece - item 33 - and rotate it counterclockwise until it engages on the connecting piece.
- Tighten the bolt - item 36 -.
- Install a new crankcase ventilation hose.
36 Bolt
• 8 Nm
37 Exhaust Gas Temperature (EGT) Sensor 1 (G235)
• 45 Nm
• Note the installed position, refer to => [ Installed Position, EGT Sensor 1 with
Angled Shaft ].
• Coat only the threads with hot bolt paste (G 052 112 A3).
Installed Position, EGT Sensor 1 with Angled Shaft
• Always adhere to dimension - a - 3 to 5 mm to the threaded connection on the turbocharger support when installing the EGT sensor 1 with an angled shaft.