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.
Disconnect battery terminals. Raise engine cover at points -1- and remove engine cover by moving forward in -direction of arrow-. Unscrew heat shield above turbocharger -arrow-. Open and close expansion tank cap to relieve pressure in cooling system. Drain coolant. Remove radiator fan -V7- with air intake. Follow the rules for maintaining cleanliness. Remove connecting hoses -1- and coolant hoses -3-. Remove bracket -2- and fastening nuts -4- for turbocharger.
Unscrew the fastening screw -2- and remove the upper coolant pipe.
Note: The lower coolant pipe can only be removed after the catalytic converter has been removed.
Unscrew bolts -1- and remove pressure pipe.
Depending on the vehicle's equipment, remove the noise insulation or the underride guard. Pull out lambda probe wiring after catalytic converter -G130- and alternator wiring duct -arrows-.
Disconnect connector for lambda probe downstream of catalytic converter -G130- and remove. Loosen clamp -3- and remove charge air pipe -2-. Unscrew exhaust pipe at catalytic converter -arrows-.
Unscrew the screws for the muffler exhaust pipe -arrows-,
Loosen double bracket bolts -arrows- and pull exhaust pipe back.
Remove also the exhaust pipe with split element. Remove catalytic converter downwards. Removing the V-ribbed belt. Unscrew securing bolts for tensioning element -arrows- and remove.
Remove air conditioner compressor.
Instructions: The lines of the air conditioning system must not be opened.
Attach the air conditioner compressor to the radiator frame. Do not kink lines. Unscrew securing bolt -arrow- for oil return pipe 2 in turbocharger.
Pull down the oil return pipe. Unscrew charge air hose -1- at turbocharger, Unscrew hollow screws for oil supply line -arrows- in turbocharger and timing housing.
Remove oil supply line. Remove all securing nuts for exhaust manifold -1-. Remove exhaust manifold with turbocharger upwards.
Note: The turbocharger may only be replaced with an exhaust manifold.
Installation
Installation in reverse order. Gaskets, lip seals and self-locking nuts must be replaced. When installing a new turbocharger, also replace the oil supply line. Pour engine oil into the turbocharger through the connecting pipe of the oil supply line. After installing the turbocharger, let the engine idle for about 1 minute without revving to ensure proper oil supply to the turbocharger. Degrease hose connections and charge system hoses before installation. Fasten all hose connections with clamps corresponding to those installed at the factory. Install the exhaust system and align it without mechanical stress. When installing air pipes with a connector, make sure that the safety clip -arrow- clicks into place in the bracket -A-.
Press engine cover at points -1- in -direction of arrow- downwards until it snaps into place at these points.
Visitor comments