Turbocharger 1. Air duct hose; 2. Pulsation damper; 3. Return oil line; 4/16/25. Bolt: 9 Nm; 5. Gasket: replace; 6. Threaded nipple: 40 Nm; 7. Gasket: replace; 8. Bolt: 20 Nm; 9. Turbocharger: can only be replaced together with the vacuum drive; 10. Gasket: replace; 11. Nut: replace; lubricate the threads with heat-resistant paste; heat resistant paste; 24 Nm; 12. Diesel particulate filter; 13. Exhaust gas temperature sensor 1 "G235"; 14. Hollow bolt: 30 Nm; 15. Oil supply line: check for patency; before installing the turbocharger, fill the oil supply line nipple with oil; tighten the union nuts to 22 Nm; 17. O-rings: replace; 18. Exhaust manifold; 19. Nut: replace; lubricate the threads with heat-resistant paste; heat resistant paste; 24 Nm; 20. Vacuum hose; 21. Crankcase ventilation hose: equipment option for countries with cold climates: with resistive heating element of the crankcase ventilation system "N79"; 22. Air guide tube; 23. Turbocharger support; 24. Bolt: 40 Nm
Removal
Caution! 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 performed. Check the air filter housing and filter element, as well as the air supply hoses for contamination. Check the entire boost air supply system and intercooler for foreign objects. If foreign objects are found in the boost air system, clean the boost air supply lines and replace the intercooler if necessary.
Remove the engine casing "arrows". Remove the air filter housing.
Disconnect the engine crankcase ventilation hose "2" and release it by pressing the release buttons. Remove the air duct hose by loosening the hose clamp "1".
Remove noise insulation screens "1" and "2". Remove the exhaust pipe. Remove the right front wheel.
Disconnect connector "4" of exhaust gas temperature sensor 3 "G495". "Pos. 1, 2, 3" do not take into account.
Unclip and disconnect the plug connector "C" of the exhaust gas temperature sensor 4 "G648" H3 of the bracket "B". Ignore "Pos. A" and "arrows".
Disconnect connector "3" of differential pressure sensor "G505". Unscrew bolt "2" and release hoses "1" on the bracket. Put differential pressure sensor "G505" back.
Vehicles with SCR catalytic converter: Disconnect electrical plug connection "2". Ignore "Pos. 1,3".
Release the exhaust pipe at the mount "2". Ignore "Pos. 1".
All
Remove cover "1" of the drive shaft in the right wheel arch.
Loosen the threaded connections "arrows", move the clamping sleeve back and tie the exhaust pipe from above.
Unscrew bolt "2" of the diesel particulate filter hanger. Ignore "Pos. 1".
Remove the air duct hose and push it to the side; to do this, loosen the "arrow" clamp.
Unscrew bolts "1" and "2", remove the turbocharger support.
Unscrew the union nut "2". Remove from the holder and disconnect the electrical plug connection "3" of the exhaust gas temperature sensor 1 "G235", release the electrical wire. "Pos. 1" do not take into account.
Remove the lambda probe "G39" "pos. 1".
Unscrew the "arrow" nuts and push the particulate filter back.
Unscrew the union nut "2". Ignore "Pos. 1".
Disconnect the electrical plug connection "1". Remove the vacuum hose "2". Unscrew the nuts "arrows", remove the pipe pump. Close the open lines and pipes with clean plugs from the plug kit for the engine "VAS 6122".
Installation
Installation in reverse order, note the following: Replace the gasket, nuts and O-ring. Fill the turbocharger with oil through the oil feed pipe nipple. To ensure that oil is supplied to the turbocharger, run the engine for about 1 minute at idle speed after installing the turbocharger; do not give the engine high revs. Install the particulate filter. Install the right front wheel. Install the exhaust pipe. Connect the air duct hose using threaded clamps.
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