Caution: If mechanical defects of the turbocharger are found, for example, the destruction of the impeller of the pump sections, it is not enough just to replace the turbocharger. In order to avoid subsequent damage, after carrying out repair work is necessary. Check the air filter housing, filter element and air intake hoses for contamination. Check for foreign bodies in the intake tract and intercooler. If found, remove them from the intake tract, if necessary, replace the intercooler.
Remove the air filter housing. Remove soundproofing. Remove the front right fender liner or the front right fender liner. Drain coolant, Remove engine skin*. Disconnect the plugs from the ignition coils and shift the wiring harness to the 8th side.
Disconnect coolant line to coolant expansion tank -arrow-.
Detach vacuum line -1- at disconnection point -2- and move vacuum line clear. Detach coolant hoses -arrows- from coolant pipe. Unscrew earth wire -3- and loosen bolt -4-.
CAWA, CAWB
Press catches, remove air hose -1- and lay to one side. Unscrew bolt -arrow- for air pipe. Remove air duct by loosening hose clamp -2-.
CCTA, CCTB
Unscrew bolt -arrow- for air pipe. Detach hose clamp -2- and place air duct on cylinder head.
All
Seal turbocharger with plug from engine set -VAS 6122-. Unscrew bolts -1...3- and remove heat shield together with coolant pipe.
Instruction: Unscrew the bolt -2- of the heat shield using a 6 mm hexagon socket -A. The hexagon shape must be at least 5 cm long -B-. The nozzle, which at the end tapers to 6 mm, has a large thickness.
Unscrew oil supply line -4- from turbocharger.
Remove screws -arrows-. Remove the air duct, to do this lift the clips -1 and 2-.
All wheel drive vehicles
Remove the heat shield above the right drive shaft.
Front wheel drive vehicles
Unscrew heat shield for right drive shaft -arrows-.
All
Remove exhaust pipe with catalytic converters. Disconnect electrical connectors -1 and 2- and move electrical cable -arrows- clear.
Vehicles with auxiliary heater
Unscrew bolts -1 and 2- and swivel coolant pipes to the left.
All
Remove bolt -1- using socket XZN 10 -T10154-. Remove bolt -2-.
Remove banjo bolt -2- and move coolant lines to one side.
Front wheel drive vehicles
Remove screws -1- for oil drain line.
All wheel drive vehicles
Unscrew the oil drain line from the engine crankcase.
All
Remove screw -3- for oil supply line.
Detach and move coolant hose -arrow-.
Remove nuts -arrows-. Remove turbocharger/exhaust manifold upwards.
Installation
Caution: If mechanical defects of the turbocharger are found, for example, the destruction of the impeller of the pump section, it is not enough just to replace the turbocharger. In order to avoid subsequent damage, after carrying out repair work is necessary. Check the air filter housing, filter element and air intake hoses for contamination. Check for foreign bodies in the intake tract and intercooler. If found, remove them from the intake tract, if necessary, replace the intercooler.
Installation is carried out in the reverse order, while observing the following. Gaskets, lip seals and self-locking nuts must be replaced. Fill the turbocharger with engine oil through the oil feed connection. After installing the turbocharger, let the engine idle for about 1 minute without revving to ensure proper oil supply to the turbocharger. The coolant return line must be installed together with the turbocharger. Degrease hose connections and charge system hoses before installation. Only the lip seals and sealing surfaces should be lightly oiled for nipple connections. Use clamps of the appropriate series to fasten all hose connections.
Torque
Exhaust manifold/turbocharger to cylinder head 1) 2) | follow the required tightening sequence |
Oil supply line to turbocharger | 20 Nm + 45° |
Oil return line to turbocharger | 9 Nm |
Coolant supply line to turbocharger | 20 Nm + 45° |
Turbocharger bracket to cylinder block 2) | 30 Nm |
Turbocharger bracket to turbocharger 2) | 30 Nm |
Charge air pipe on the right to the oil pan | 10 Nm |
Heat shield for MCC M8 and M12 | 20 Nm |
1) Replace nuts.
2) Use heat resistant grease.
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