Table of contents: Removal the turbocharger ↓ Tightening torques ↓
Hose routing and turbocharger - exhaust location
- 1 - carbon filter;
- 2 - fuel tank ventilation pipe;
- 3 - carbon filter check valve;
- 4 - turbocharger;
- 5 - fuel pressure regulator;
- 6 - intake manifold;
- 7 - crankcase ventilation;
- 8 - carbon filter check valve;
- 9 - throttle valve pipe;
- 10 - charge air radiator;
- 11 - boost pressure regulator vacuum box;
- 12 - draft shut-off valve;
- 13 - boost pressure limiting electromagnetic valve;
- 14 - crankcase ventilation pressure limiting valve;
- 15 - carbon filter electromagnetic valve.
Before replacing a suspected faulty turbocharger, in addition to the faults listed in the fault help table, the following functions or possible sources of faults should be checked: boost pressure control units, fuel supply, injection, ignition, compression and air filter.
Tip: After running the engine at full load for a long time, let it idle for a while before turning it off.
Removal the turbocharger
When working on a turbocharger, cleanliness must be maintained. Before disconnecting, thoroughly clean the connection points and their surroundings, place dismantled parts only on a clean lining, cover open units to protect against 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 cable.
2. Remove the air filter.
3. Disconnect the air hoses from the turbocharger.
4. Clamp the water hoses to the turbocharger tightly and remove.
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. For this, use a SW 12 offset spanner.
10. Hold the turbocharger firmly while unscrewing and lift it up.
11. Installation: Use new nuts and bolts. Lubricate the turbocharger flange/exhaust manifold elbow bolts with "G 000 500" grease in the thread area and the bearing surfaces of the heads.
12. Install the turbocharger with all bolts and nuts first so that it can move a little. To do this, just tighten the mounting nuts/bolts slightly.
13. Install the four turbocharger mounting bolts to the exhaust manifold and tighten to the specified torque.
14. Only then tighten the nuts on the exhaust pipe.
15. Before connecting the oil supply hose, you must first pour some fresh engine oil into the connecting pipe on the compressor.
16. After installing the turbocharger, do not immediately start the engine at high speed, as the compressor lubrication is still unreliable.
17. Let it idle for one minute.
Tightening torques
|
Details
|
Nm
|
| Compressor mount (flange nut M10) |
60
|
| Catalytic converter in turbocharger |
30
|
| Turbocharger Oil Supply Hose |
25
|
| Turbocharger Oil Return Hose |
30
|
| Turbocharger Coolant Supply Hollow Bolt |
25
|
| Turbocharger Coolant Return Hose |
35
|