Removing
Attention.
- If a turbocharger has a mechanical problem, such as a damaged impeller, it is not enough to simply replace the turbocharger. To prevent further damage, the following work must be carried out:
- Clean out all lubrication lines.
- Change engine oil and replace oil filter.
- Check the air filter housing and air intake pipes for contamination.
- Check the entire charge air path and charge air cooler for foreign particles.
- If foreign bodies are found in the charge air system, the entire charge air path must be cleaned and, if necessary, the charge air cooler must also be replaced.
1. Disconnect the negative terminal from the battery.
2. Remove the V-ribbed implement drive belt (for details, see the relevant section in chapter Gasoline engines).
3. Drain the coolant.
4. Disconnect hoses (1) and wiring harness connector (2) from the turbocharger as shown in the figure below.
5. Unscrew the fastening screws (1), and unfasten the clamp as shown in the figure below.
6. Disconnect the wiring harness connector (2), shown in the figure below from charge pressure sender -G31- with intake air temperature sender 2 -G299-.
7. Release the locks in the direction of the arrow, disconnect the pressure pipe (3) first from the throttle valve module -J338- and then from the turbocharger as shown in the figure below.
8. Open the lid (4) and unscrew the fastening screw, as shown in the figure below.
9. Using a special puller (T10112 A), disconnect high-voltage wires from spark plugs (arrows), as shown in the figure below. Set high voltage wires aside.
10. Disconnect the hoses from the pipes of the cooling system (1), as shown in the figure below.
Note. Check that oil does not flow into the alternator! To avoid the above, cover the generator with a clean rag.
11. Unscrew the hollow screw (4) lubrication line as shown in the figure below.
12. Unscrew the fastening screws (2) And (3), remove the lubrication line and coolant pipe as shown in the figure below.
13. Remove lambda probe -G39- (5), shown in the figure below.
14. Unscrew the upper screw securing the alternator, take the alternator down a little.
15. Unscrew the fastening screws (arrows) and remove the thermal insulation cover of the turbocharger as shown in the figure below.
16. Remove mounting bracket (1), shown in the figure below.
17. Remove the exhaust gas catalyst together with the front of the exhaust pipe.
18. Unscrew the fastening screw (1) drain lubrication line (2), remove the oil drain line from the turbocharger as shown in the figure below.
19. Unscrew the screws securing the thermal insulation cover (3), then remove the thermal insulation cover from the exhaust manifold.
20. Unscrew all fastening nuts (arrows) exhaust manifold shown in the figure below.
21. Disconnect and remove the exhaust manifold/turbocharger assembly from the cylinder head.
22. Remove the seal from the studs on the cylinder head.
Installation
1. Install the turbocharger with exhaust manifold and gasket on the cylinder head.
2. Tighten the fastening nuts in the sequence shown in the figure below with (A) By (H) with a tightening torque of 18 Nm.
3. Further, installation is carried out in the reverse order of removal, taking into account the conditions below.
Note.
- Replace seals, O-rings and self-locking nuts.
- The turbocharger must be filled with engine oil through the lubrication line connection.
- After installing the turbocharger, leave the engine running for approximately 1 minute at idle to allow oil to circulate through the turbocharger.
- Before proceeding with the installation of the hose connections and the charge air hoses themselves, it must be ensured that they are free of oil and grease.
- All hose connections must be secured with appropriate hose clamps.
4. Fix the alternator (for details, see the relevant section in chapter Engine electrical equipment).
5. Install the V-ribbed implement drive belt (for details, see the relevant section in chapter Gasoline engines).
6. Fill the systems with the required amount of coolant.
7. Connect the negative terminal to the battery.