Turbocharger

Turbocharger

Special tools, testers and auxiliary items required

• Engine Bung Set (VAS 6122)

Removing

If mechanical damage, such as a destroyed compression wheel is found on the turbocharger, just replacing the turbocharger is not enough. To avoid damage later, perform the following steps:

• Check the air filter housing, air filter element and charge air hoses for contamination.

• Check the entire charge air circuit and charge air cooler for foreign objects.

• If there are foreign objects in the charge air system, clean the charge air circuit and replace the charge air cooler, if necessary.

- Remove the engine cover. Refer to => [ Engine Cover ] Engine Cover.

- Loosen the spring clamps - arrows - and remove the charge air hose.






- Remove the bolts - 2 and 3 -.






- Loosen the clamp - 1 - and remove the charge air pipe from the charge air hose forward.

- Remove the bolts - left arrows - and move the air intake connection to the side with the air duct hose still connected - right arrow -.






- Disconnect the connector - 2 - from the turbocharger 1 servo motor.






- Remove the bolt - 1 - and the banjo bolt - 3 - for the oil supply line from the turbocharger.

- Remove the bolts - 1 -, loosen the bolt - 2 - and remove the turbocharger heat shield.






- Cover the opening - arrow - in the transmission to prevent small parts from falling inside.






• The illustration shows the intermediate pipe removed.

• Ignore - 1 and 2 -.

- Remove the nuts - arrows - and remove the front exhaust pipe with catalytic converter from the turbocharger.






- Disconnect the exhaust gas temperature sensor 1 connector (black) - 3 -.






- Remove the turbocharger bolts - arrows -.













Danger of damaging both pipes for the oil return line.

• The upper part - 3 - of the oil return line mounted to the turbocharger must be removed carefully from the lower part - 5 - of the oil return line.

• Gently turning the turbocharger - 4 - back and forth and pulling it up will prevent bending the oil return line pipes.

1. O-ring

2. Intermediate flange


- Remove the turbocharger.

- Seal the open lines and connections with plugs from the engine bung set (VAS 6122).

• Do not set the removed turbocharger on the upper part of the oil return line.

Installing

• Replace gaskets, seals and O-rings.

• Hose connections and charge air system hoses must be free of oil and grease before installing.

• Secure all hose connections using hose clamps appropriate for the model type. Refer to the Parts Catalog.

• To install the charge hoses to their connections securely, spray the bolts on the used clamps with rust remover before installing.

• During installation, install all heat insulation sleeves at the same locations.

• Add oil to the turbocharger through the oil supply line connection.

• After installing the turbocharger, allow the engine to idle for approximately 1 minute without increasing the engine speed. This ensures adequate oil supply to the turbocharger.

- Slide the connecting hose - 1 - and both hose clamps - 2 - onto the turbocharger connection to prepare the turbocharger for installation.






- Install the new O-ring - 1 - on the lower section - 5 - of the oil return line.






- Lightly oil the O-ring and the inner sealing surface on the upper section - 3 - of the oil return line.

- Guide the oil return line upper section - 3 - through the intermediate flange - 2 - to the oil return line lower section - 5 - when installing the turbocharger - 4 -.

- Carefully position the oil return line upper section on the lower section.

The O-ring must not be damaged.

- Install and tighten the turbocharger bolts - arrows -.






Further installation is in the reverse order of removal. Note the following:

- Install the front exhaust pipe with catalytic converter.

Tightening Specifications






• 1 Replace bolts/nuts.

• 2 Coat with hot bolt paste. Refer to the Parts Catalog.