Exhaust Manifold: Service and Repair

Turbocharger With Attachments, Removing And Installing

Observe rules for cleanliness. [1][2]Technician Safety Information

NOTE:
- All hose connections are secured with clamps.
- VAS5024A spring clip installation tool is recommended for installing spring-type clamps.







- Charge air system must be properly sealed.
- Charge pressure hoses and pipes as well as their connections must be free of oil and grease before re-installation.
- Always replace self-locking nuts.

Assembly Overview







1 Exhaust manifold
- with turbocharger
- Replace as complete unit only
2 Intake manifold
3 From charge air cooler
4 Seal
- Coating (bead) to intake manifold
5 25 Nm
6 Seal
- Note installed position
7 Bracket
- For shielding plate, item no. 9
8 Washer
9 Heat shield
- Engages in bracket, item no. 7
10 Turbocharger
- Replace as complete unit with exhaust manifold only
- To remove the exhaust turbocharger, disconnect right drive axle from transmission:
- After installing turbocharger, let engine idle for approx. 1 minute without increasing engine speed. This ensures adequate oil supply to the turbocharger.
11 Vacuum diaphragm
- For boost pressure regulation
- Part of turbocharger, cannot be replaced
12 From air filter
13 Seal
14 Seal
15 Oil return line
- to cylinder block
- new version See Fig. 1
16 Banjo fitting, 40 Nm
17 15 Nm
18 40 Nm
19 Brace
- Turbocharger - cylinder block
- new version See Fig. 1
20 25 Nm
21 Seal
22 Front exhaust pipe
23 Connecting piece
- Coat threads and bolt head contact surface with G 052 112 A3
24 10 Nm
25 Oil supply line
- Before installing, fill turbocharger with oil at connection of oil supply line
- Tighten to 22 Nm

Fig. 1 New version of oil return line and support







1 Support for turbocharger - cylinder block
2 40 Nm
3 Connection, 40 Nm
4 Oil return line with union nut
Tighten to 30 Nm on cylinder block
5 15 Nm
6 Seal
7 25 Nm