Hose Routing and Location Turbocharger - Exhaust
- 1 - carbon filter;
- 2 - ventilation tube of the fuel tank;
- 3 - return valve of the coal filter;
- 4 - turbocharger;
- 5 - fuel pressure regulator;
- 6 - intake manifold;
- 7 - crankcase ventilation;
- 8 - return valve of the carbon filter;
- 9 - throttle valve pipe;
- 10 - charge air cooler;
- 11 - vacuum box boost pressure regulator;
- 12 - thrust shutoff valve;
- 13 - solenoid valve for boost pressure limitation;
- 14 - crankcase ventilation pressure limiting valve;
- 15 - carbon filter solenoid valve.
Before a suspected faulty turbocharger is replaced, in addition to the defects listed in the troubleshooting table, check the following functions or possible sources of defects: boost pressure control, fuel delivery, injection, ignition, compression and air filter components.
Tip: After an extended full load, let the engine idle for a while before shutting down.
Dismantling the turbocharger
Cleanliness must be observed when working on the turbocharger. Before disconnecting, thoroughly clean the connecting points and their surroundings, place the dismantled parts only on a clean pad, cover exposed parts to protect them from contamination, install only clean new parts, do not work with compressed air near the repair site and do not move the car.
1. Disconnect the battery ground wire.
2. Remove the air filter.
3. Disconnect the air hoses from the turbocharger.
4. Press the water hoses to the turbocharger tightly and remove them.
5. Unscrew the exhaust hanger from the gearbox.
6. Unscrew the catalytic converter from the turbocharger (four nuts).
7. Unscrew the oil supply hose from the turbocharger.
8. Unscrew the oil return hose from the turbocharger.
9. From below, unscrew the mounting bolts that secure the turbocharger to the exhaust manifold. To do this, use a curved slip spanner SW 12.
10. Hold the turbocharger firmly while unscrewing and lift it up.
11. Mounting: Use new nuts and bolts. Lubricate the turbocharger flange/exhaust manifold elbow bolts with grease «G 000 500» in the thread area and bearing surfaces of the heads.
12. Install the turbocharger with all bolts and nuts first so that it can move slightly. To do this, tighten the fixing nuts / bolts only slightly.
13. Screw in four fixing bolts for fastening of a turbocharger at a final collector and tighten taking into account the necessary moment of an inhaling.
14. Only then tighten the nuts on the downpipe.
15. Before connecting the oil supply hose, you must first pour a little fresh engine oil into the connecting pipe on the compressor.
16. After installing the turbocharger, do not immediately start the engine at high speeds, as the compressor lubrication is still unreliable.
17. Let it run for one minute at idle.
Tightening torques
Details
|
Nm
|
Compressor mount (collar nut M10) |
60
|
Catalytic converter at turbocharger |
30
|
Oil supply hose to turbocharger |
25
|
Oil return hose from turbocharger |
30
|
Hollow bolt for coolant supply to turbocharger |
25
|
Coolant return hose from turbocharger |
35
|
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