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Removing and installing exhaust manifold with
turbocharger
 Remove
| 1. |
Remove air intake manifold
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| 2. |
Remove engine vent hose from cylinder head cover
|
| 3. |
Detach air intake pipe from air intake hose
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| 4. |
Detach air intake pipe from turbocharger
| • |
Release clamp (3)
Note: Seal air intake
pipe at turbocharger
|
|
| 5. |
Remove air intake pipe
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|
|
| 6. |
Remove charge air hose (2)
|
|
|
| 7. |
Remove engine vent hose (3) from engine vent flange and
cylinder head cover.
|
| 8. |
Detach upper coolant pipe (1) with engine transport shackle
from cylinder head
|
| 9. |
Lay aside upper coolant pipe
|
| 10. |
Remove bolt from top of heat shield (2)
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|
|
| 11. |
Disconnect wiring harness plug for mixture regulating oxygen
sensor (1) and expose wiring harness (2)
.
|
| 12. |
Open coolant drain bolt
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|
|
| 13. |
Close coolant drain screw
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| 14. |
Detach front exhaust pipe from starter catalytic converter
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| 15. |
Remove oil drain bolt
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| 16. |
Install oil drain bolt with new seal ring 10 Nm
|
| 17. |
Detach lower turbocharger charge air hose from turbocharger and
lay aside
|
| 18. |
Remove lower heat shield fastening bolt
|
| 19. |
Detach banjo bolt (3) from cylinder block
Note: Place collecting
basin underneath.
|
| 20. |
Remove 2x bolt (1) and remove oil return line (2)
|
|
|
| 21. |
Place collecting basin underneath.
|
| 22. |
Remove turbocharger oil feed line union nut (3) (cylinder
block)
|
| 23. |
Remove mounting bolt (1) for turbocharger oil feed line bracket
(turbocharger) (2) from cylinder block
|
|
|
| 25. |
Remove 2x bolt (1) and remove engine vent pipe.
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| 26. |
Clean sealing surfaces.
|
|
|
| 27. |
Detach coolant hose (4) from turbocharger coolant pipe
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| 28. |
Detach coolant hose (3) from radiator
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| 29. |
Unclip coolant hose from fan housing
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| 30. |
Disconnect boost control wiring harness plug (2)
|
| 31. |
Disconnect boost control vacuum hose (1)
|
| 32. |
Detach exhaust manifold with turbocharger and starter catalytic
converter from cylinder head and remove from above
|
|
|
| 33. |
Clean sealing surfaces and remove gasket remnants.
|
| 34. |
Check stud bolt on cylinder block for corrosion
Note: Re-cut with M8
die
|
| 35. |
Coat stud bolt with assembly paste (white)
|
Install
| 36. |
Attach exhaust manifold to cylinder head with new gasket and
new fastening nuts.
|
| 37. |
Step 1 - Tighten exhaust manifold in depicted sequence 8 Nm .
|
| 38. |
5 minutes waiting time
|
| 39. |
Step 2 - Re-tighten exhaust manifold in depicted sequence 8 Nm
Note: Be sure to adhere
to tightening order and tightening torque, otherwise the
turbocharger may be damaged
|
|
|
| 40. |
Connect boost control vacuum hose
|
| 41. |
Connect boost control wiring harness plug
|
| 42. |
Clip coolant hose to fan housing and attach to radiator
|
| 43. |
Attach coolant hose to turbocharger coolant pipe
|
| 44. |
Fit new gasket (2)
Note: Note installation
position, bead (3) must point upward towards engine vent flange
|
| 45. |
Attach engine vent flange to cylinder block 25 Nm
|
| 46. |
Attach heat shield to exhaust manifold 9 Nm
|
| 47. |
Attach front coolant pipe with engine transport shackle to
cylinder head 20 Nm
|
| 48. |
Insert heat shield and attach upper heat shield to cylinder
head fastening bolt
Note: Do not
tighten
|
| 49. |
Attach lower heat shield fastening bolt 9 Nm .
|
| 50. |
Connect turbocharger oil feed line (turbocharger) to
turbocharger oil feed line (cylinder block) 20 Nm .
|
| 51. |
Attach turbocharger oil feed line bracket (turbocharger) to
cylinder block 35 Nm .
|
| 52. |
Attach turbocharger oil feed line to turbocharger 8 Nm
Note: Use new
gasket
|
| 53. |
Attach turbocharger oil feed line to cylinder block 30 Nm
Note: Use new
gaskets
|
| 54. |
Attach lower charge air hose to turbocharger 3.5 Nm
|
| 55. |
Attach front exhaust pipe to starter catalytic converter 35 Nm
|
| 56. |
Tighten top heat shield bolt 9
Nm
|
| 57. |
Connect wiring harness plug for mixture regulating oxygen
sensor and route wiring harness
|
| 58. |
Attach upper coolant pipe with engine transport shackle to
cylinder head 20 Nm
|
| 59. |
Attach engine vent hose to engine vent flange and cylinder head
cover
|
| 61. |
Remove seal from turbocharger air intake pipe
|
| 62. |
Attach engine vent hose to cylinder head cover
|
| 63. |
Attach air intake pipe to turbocharger
|
| 64. |
Attach air intake pipe to air intake hose
|
| 66. |
Fill with oil up to "MAX" mark on oil dipstick.
|
| 67. |
Always use antifreeze 19 40 650 / 9194431 (red) and ensure that
the concentration is 50% water and 50% antifreeze. The antifreeze
does not just protect the entire cooling system from freezing, but
also protects all coolant-flushed parts from rust-corrosion/calcium
deposits. It is therefore important to add antifreeze, even in
tropical countries.
|
| 68. |
The water quality also plays an important role in addition to
the mix ratio. Water of drinkable quality usually meets these
requirements. The quality of purified sea water is inadequate!
|
| 69. |
Damage may also be caused to the engine if unauthorised
anti-freeze agent is used!
|
| 70. |
If radiator, cylinder head or cylinder head gasket have been
replaced the old coolant must not be re-used.
|
Important: Vehicles with air
conditioning: switch air conditioning off and set to ECO mode with
ECC
|
| 71. |
Open cooling system
Warning: Cooling system is under
pressure
|
| • |
Unscrew coolant expansion tank cover
|
|
| 72. |
Fill with coolant up to lower venting line (1) at coolant
expansion tank
|
| 73. |
Seal off cooling system
| • |
Screw in coolant expansion tank cover
|
|
| 74. |
Start engine and allow to warm up
| • |
Allow engine to warm up at idling speed of up to 2500 rpm until
first radiator fan setting switches on
|
|
| 75. |
Vent cooling system
| • |
Allow engine to run for approximately 2 minutes at 2000 to 2500
rpm
Note: The air in the
cooling system is removed via the venting lines
|
|
| 76. |
Switch engine off and allow to cool
|
| 77. |
Check coolant level and also top up coolant to "COLD" mark
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