Exhaust Manifold with Turbocharger, Replace
Remove
3. |
Remove engine cover (2)
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Detach oil filler port closure cap (1)
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Pull off engine cover
Note: Rubber retainers
(3) must remain on engine cover
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Attach oil filler port closure cap
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4. |
Raise vehicle by its full height
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5. |
Remove engine splash protection right or engine compartment
cover lower
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6. |
Drain coolant
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Open drain bolt on radiator (1)
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7. |
Remove ribbed V-belt
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Mark direction of rotation
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Apply tension to ribbed V-belt tensioner via bolt (1) in the
direction of the arrow
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Fix ribbed V-belt tensioner to bore (2)
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8. |
Detach front exhaust pipe
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From start-up catalytic converter
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9. |
Place collecting basin underneath.
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10. |
Drain engine oil
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Unscrew oil drain bolt (1)
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Tighten oil drain bolt 78.4 Nm
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11. |
Detach oil dipstick guide tube from upper part of oil pan
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12. |
Detach turbocharger oil return hose (1) from turbocharger
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13. |
Detach turbocharger oil feed line (1) from cylinder block
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14. |
Detach start-up catalytic converter from bracket
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15. |
Disconnect vacuum hose (2) from turbocharger control unit
(1)
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16. |
Lower vehicle by its full height
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17. |
Release compressor (1)
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Disconnect wiring harness connector.
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Unscrew 3 bolts
Note: Note different
bolt lengths
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Attach compressor top to vehicle front
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18. |
Remove compressor bracket (1)
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19. |
Remove air intake manifold (1)
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20. |
Remove bracket, oil dipstick guide tube (1)
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Remove oil dipstick guide tube
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Detach bracket, oil dipstick guide tube, from camshaft
housing
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21. |
Remove upper charge air hose (1)
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22. |
Remove lower charge air hose
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23. |
Release heat exchanger, exhaust gas recirculation
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Detach from camshaft housing
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Detach from exhaust gas recirculation port
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Detach from intake manifold
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Unscrew 2x bolts (arrow)
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24. |
Remove heat exchanger, exhaust gas recirculation
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25. |
Remove exhaust manifold heat shield
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26. |
Detach turbocharger oil feed line from turbocharger
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27. |
Remove exhaust manifold (1) with turbocharger
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28. |
Clamp exhaust manifold (1) in vice
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29. |
Remove heat shield, start-up catalytic converter (4)
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30. |
Detach catalytic converter (3) from turbocharger
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31. |
Detach turbocharger (2) from exhaust manifold
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Install
32. |
Clean sealing surface
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33. |
Attach turbocharger to exhaust manifold
Note: Fill 0.4 ml clean
engine oil into the aperture of the oil feed line
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Tighten 3x new nuts 26.5 Nm
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34. |
Attach catalytic converter to turbocharger
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35. |
Install heat shield, start-up catalytic converter
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Tighten 3x bolt 11.7 Nm
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36. |
Remove exhaust manifold from vice
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37. |
Insert exhaust manifold with turbocharger
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38. |
Attach turbocharger oil feed line to cylinder block
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39. |
Attach exhaust manifold with turbocharger
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40. |
Attach turbocharger oil feed line to turbocharger
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41. |
Install exhaust manifold heat shield
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Tighten 4x bolt 11.7 Nm
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42. |
Attach vacuum hose to turbocharger control unit
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43. |
Install heat exchanger, exhaust gas recirculation
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Attach to exhaust manifold
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Tighten 2x bolts 28.5 Nm
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Attach to exhaust gas recirculation port
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Tighten 2x bolts 28.5 Nm
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44. |
Install lower charge air hose
Important: Groove (1) must engage
in projection (2)
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Tighten 2x clamp 3.5 Nm
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45. |
Install upper charge air hose
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Tighten 2x clamp 3.5 Nm
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46. |
Attach upper coolant hose to heat exchanger exhaust gas
recirculation
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47. |
Install bracket, oil dipstick guide tube
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Attach bracket, oil dipstick guide tube, to camshaft
housing
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Attach dipstick guide tube
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48. |
Install air intake pipe.
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49. |
Install compressor bracket
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50. |
Install compressor
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Tighten 3x bolt 24.5 Nm
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Fix wiring harness plug
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51. |
Install engine cover
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Detach oil filler port closure cap
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Attach oil filler port closure cap
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52. |
Raise vehicle by its full height
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53. |
Attach turbocharger oil feed line to cylinder block
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Tighten banjo bolt 27.5 Nm
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54. |
Attach oil return hose to turbocharger
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55. |
Attach oil dipstick guide tube to upper part of oil pan
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Tighten 2x bolts 9.8 Nm
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56. |
Attach start-up catalytic converter to bracket
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57. |
Attach front exhaust pipe to start-up catalytic converter
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58. |
Insert ribbed V-belt
Note: Note running
direction of ribbed V-belt
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Position ribbed V-belt
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I. Ribbed V-belt without air conditioning
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II. Ribbed V-belt with air conditioning
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Apply tension to ribbed V-belt tensioner via bolt (1) in the
direction of the arrow
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Release ribbed V-belt tensioner
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59. |
Install lower engine cover and right engine splash guard
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60. |
Lower vehicle by its full height
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61. |
Cooling System, Charge and Bleed
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62. |
Top up engine oil, check oil level
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64. |
Program volatile memories
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