Turbocharger. I 1. Connecting pipe: to the EGR radiator switch valve; 2/28/37. Gasket: replace; 3. Intermediate flange; 4/38. Bolt: 25 Nm; 5. Rear right cooling system pipe; 6. Seal ring: replace; 7/9/10/17/21/39. Bolt: 9 Nm; 8. Oil supply line: from the cylinder block; 11. Seal rings: replace; 12. Hollow bolt: 15 Nm; 13. Right air tube; 14/16. Hose clamp: reinforced; 5.5 Nm; 15. Air hose: from the turbocharger to the right air duct; 18. Air connection pipe. hose: from air mass meter -G70- to turbocharger; Before installation, remove oil and grease; 19. Exhaust temperature sensor 1 -G235-; 20. Sealing lip: replace if damaged; 22. Turbocharger heat shield; 23. Turbocharger; 24. Bolt: replace; grease with heat-resistant paste; 30 Nm + 90°; 25. Gasket: replace; 26. Particulate filter; 27. Nut; 29. Bolt: lubricate with heat-resistant paste; pre-tighten to 7 Nm; 9 Nm; 30. Upper oil return pipe: from the turbocharger; 31. Bolts: 9 Nm; 32. Lower oil return pipe: to the cylinder block; 33. Seal rings: replace; 34. Gasket: replace; 35. Intermediate tube; 36. Bolt
Removal
Carefully! If the turbocharger has mechanical damage (for example, damage to the impeller), it is not enough to simply replace the turbocharger. To prevent further damage, the following work must be done. Check the housing and air filter element. filter, as well as air supply hoses for contamination. Check the entire charge air supply system and intercooler for foreign objects. If foreign objects are found in the charge air system, clean the charge air supply lines and, if necessary, replace the intercooler.
Remove engine cover -arrows-. Remove the stretch. Remove air duct -arrow-. Disconnect plug connector -1- for air mass meter -G70-. Unscrew bolt -3- and release exhaust gas pressure sensor 1 -G450- -pos. 4- on the air duct pipe. Unplug and unplug connector -2 for exhaust temperature sender 4 -G648- at air duct pipe. Remove the air hose with air mass meter -G70- by unclamping the hose clamp -5- and loosening the fasteners -arrows-.
Loosen bolt -2- and unscrew bolt -3- a few turns. Remove the air duct pipe from the air duct hose by loosening the hose clamp -1-.
Unscrew the bolts -arrows on the left- and place the suction pipe with the connected air hose -arrow on the right- to the side.
Disconnect electrical connector -2 for turbocharger motor 1 -V280-. Unscrew bolt -1- and hollow bolt -3- of the oil supply line on the turbocharger
Remove connector -2- from bracket and disconnect it. -Pos. 1- do not take into account.
Release and disconnect electrical connector -1- from exhaust temperature sender 3 -G495-. Remove bolts -2- and -3-. Remove the turbocharger heat shield.
Unscrew nuts -arrows- and remove particulate filter from turbocharger.
Disconnect plug connector -1 - (black) exhaust temperature sensor 1-G235-. Remove plug connector -2- from bracket (orange) exhaust gas recirculation temperature sensor -G98- from the bracket and disconnect the connector.
Remove bolts -arrows- for turbocharger.
Risk of damage to both oil return pipes. The upper oil return pipe -3- attached to the turbocharger must be carefully removed from the lower oil return pipe -5. To prevent bending of both oil return pipes, the turbocharger -4- should be removed from the side in an upward direction, slightly tilted in different directions.
- 1. Seal ring
- 2. Intermediate flange
Remove the turbocharger. To prevent the penetration of dirt, seal the disconnected lines and pipes on the intercooler with a clean plug from the engine plug set -VAS 6122-. To avoid damage, the removed turbocharger must not be placed on top of the oil return line.
Installation
Replace seals, lip seals and seals. rings. During installation, install all heat-insulating cuffs in their original locations. Fill the turbocharger with oil through the oil supply pipe. Hose fittings, air pipes and hoses must be cleaned of oil and grease before installation. Secure all hose connections with hose clamps of the appropriate series. To ensure reliable fastening of the air hoses to the fittings, the threaded connections of already used clamps should be treated with a rust remover. To ensure that oil is supplied to the turbocharger, it is necessary to run the engine for approx. 1 minute at idle speed; do not give the engine high speeds. Install a new seal. ring -1- to the lower part -5- of the oil return line. Lubricate the seal. ring and the inner contact surface at the top of the -3- oil return line. When installing the turbocharger -4-, pass the upper part -3- of the oil return line through the intermediate flange?2- and connect it to the lower part -5- of the oil return line. Risk of damage to the seal. rings. Carefully push the upper part -3- of the oil return line onto the lower part -5- of the oil return line. Screw on the turbocharger -arrows-. Installation is in reverse order, observing the following. Install the particulate filter. Install exhaust pressure sensor 1 -G450-. Install a stretcher.
Removing the intermediate flange
Remove the particulate filter. Remove the turbocharger. Remove bolts -1- and -3-. -Pos. 2- and -arrows- are ignored.
Remove bolts -3- (3 pcs.), -4- (3 pcs.), -5- (2 pcs.), as well as -1,2,6- and remove the intermediate flange.
Installation
Install in reverse order. Replace seals. Install the turbocharger.
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