Charge air system with turbochargerRemoving and installing turbocharger with attachments

Observe rules for cleanliness => Page 21-2.

Notes:

◆ All hose connections are secured with clamps and/or securing clips.

◆ VAS 5024 A pliers are recommended when installing spring-type clips.

◆ Do not install hose connections with lubricant containing oil.

◆ Charge air system must be free of leaks.

◆ Before screwing on oil supply pipe fill turbocharger at connection with engine oil.

◆ After installing turbocharger run engine for approx. 1 minute at idling speed, do not rev engine.

This ensures that the turbocharger is adequately lubricated.

◆ Renew self-locking nuts.

Engine code AHU =>Page 21-4

Engine codes AFN, AVG, AHH =>Page 21-8

Engine code AHU

Note:

◆ After installing turbocharger run engine for approx. 1 minute at idling, do

not rev engine. This ensures that the turbocharger is adequately lubricated.

1. Exhaust manifold 2. 35 Nm

◆ Renew

◆ Coat threads and bolt head seating surface with G000500

3. Intake manifold

4. From charge air cooler5. Gasket

◆ Renew

◆ Coating (beading) towards intake manifold

6. 25 Nm 7. Gasket

◆ Note installation position 8. Washer

9. 25 Nm 10. Heat shield 11. To crankcase breather 12. From air cleaner 13. Hose

◆ To charge pressure control solenoid valve (N75)=> Page 21-20

14. Banjo bolt, 15 Nm 15. Seal

◆ Renew

16. 30 Nm 17. Oil return pipe

◆ To cylinder block

18. Banjo bolt, 30 Nm 19. Gasket

◆ Renew 20. Hose

◆ To charge pressure control solenoid valve (N75)

=> Page 21-2021. 10 Nm

◆ Install with D6 22. Pressure unit

◆ For charge pressure regulating valve

◆ Checking =>Page 21-22

◆ Removing and installing

=> Page 21-2323. Circlip 24. Turbocharger

◆ Checking => Page 21-24

◆ Checking charge pressure control=> Page 21-33

25. Gasket

◆ Renew

26. Front exhaust pipe

27. Connection, 30 Nm

◆ Renew

◆ Coat threads and bolt head seating surface with "G 052 112 A3"

◆ Before screwing on oil supply pipe fill connection with engine oil 28. Bolt

◆ Tightening torque => page 17-8, item 929. Oil supply pipe

◆ From oil filter bracket

=> Page 17-3, item 6

◆ Before screwing on oil supply pipe fill connection with engine oil

◆ Removing and installing =>page 17-8

Engine codes AFN, AVG, AHH

Note:

◆ After installing turbocharger run engine for approx. 1 minute at idling, do

not rev engine. This ensures that the turbocharger is adequately lubricated.

1. Exhaust manifold 2. Intake manifold 3. From charge air cooler 4. Gasket

◆ Renew

◆ Coating (beading) towards intake manifold 5. 25 Nm

6. Gasket

◆ Note installation position

7. Retainer

◆ For heat shield item 9

8. Washer 9. Heat shield

◆ Engage in bracket item 710. Pressure unit

◆ For charge pressure control

◆ Integral part of turbocharger cannot be replaced

11. Turbocharger

◆ Checking charge pressure control

=> Page 21-3312. To crankcase breather 13. From air cleaner 14. Gasket

◆ Renew

15. 30 Nm 16. Oil return pipe

◆ To cylinder block

17. Seal

◆ Renew 18. Banjo bolt, 30 Nm 19. Retainer20. To charge air cooler21. Gasket

◆ Renew

22. Front exhaust pipe 23. Hose

◆ To charge pressure control solenoid valve (N75)

=> Page 21-16

24. Connection, 30 Nm

◆ Renew

◆ Coat threads and bolt head seating surface with "G 052 112 A3"

◆ Fill connection with engine oil before screwing on oil supply pipe.

25. Bolt

◆ Tightening torque => page 17-8, item 926. Oil supply pipe

◆ From oil filter bracket=> Page 17-3, item 6

◆ Fill connection with engine oil before screwing on oil supply pipe.

◆ Removing and installing =>page 17-8

27. Retainer 28. 25 Nm

◆ Renew

◆ Coat threads and bolt head seating surface with G 000 500